S4C+ M2000 won’t boot

    Hi all,

    S4C+ M2000 will not boot up.

    Teach pendant reads:

    Wait!

    Startup in progress.

    and counts up indefinitely with out ever fully booting.


    I don’t have another teach pendant to try but it seems ok.

    I’ve cycled the power several times.


    The robot has not been powered up in approx 2 years.


    Here are my LED's

    -----------------------

    On the Power Supply I am green.

    ---------------------

    On the DSQC 509

    En: Nothing

    MS: Green

    NS: Nothing

    -----------------

    DSQC 504

    Nothing

    ----------------

    CPU

    PWR: Green

    HDD: Nothing

    Status: Flashing green

    ----------------------

    Can anyone please advise?


    Thank you.

    Quote from Lemster68

    Your boot image is corrupt. Look in manuals sub forum for procedure to delete boot image.

    Hi Lemster,

    Thanks for the reply.


    Your manual shows a null modem cable, can this be done with a usb to serial converter?


    Can it also be done through the RJ45 service port on the front of the controller?


    Thanks

    You probably need to use a null adapter. Get a slim DB9M/F Null modem adapter and slim DB9F/F & DB9M/M adapters too. I used to go thru 4 or 5 Null adapters a year handing them out to controls & maintenance folks. The old QVS # PSDB9X.

    I always had an old XP laptop to use HyperTerminal but did have a Win7 running TeraTerm and a USB>232 at one time. Panasonic Toughbooks and several other rough service can still provide Com ports. They're much cheaper if bought used.

    Ok so I followed the manual and it seemed to work in that I got the same responses as the manual.


    However, after entering 'reboot', after a few minutes, the Status led changes from solid red to flashing green again and I get the following responses:


    /// Bootloader 1.1/8 Nov 24 1999, 00:20:32 ///


    disk 0:0 ATA STI Flash 6.1.0

    disk 0:1 unknown type



    done.

    system: '/hd0a'

    release: '/hd0a'

    Loading module /hd0a/bin/mc 1608728 + 60144 + 1028576

    Loaded configuration /hd0a/mc.cfg

    Starting at 0x108000...



    Starting RTC synchronization of system time...


    /hd0a/ - Volume is OK

    Phys mem : 0x1fff000

    Perm pool : 0xa00000 @ 0x15ff000

    LocalCA mem : 0x18000 @ 0x88000

    LocalSM mem : 0x8000 @ 0x80000

    Local mem : 0x15ff000.

    BSP version : 1.1/15

    Creation date: May 19 2005 02:55:55

    Main network : fei0 100.100.100.14 00:01:af:0a:cf:dd



    Executing startup script /hd0a/bin/mc.bat ...

    mRouteAdd "192.168.125.64","192.168.125.2",0xffffffe0,0,0

    value = 0 = 0x0

    sp root_entry,"bin/install.cmd"

    task spawned: id = 0xcb5914, name = t1

    value = 13326612 = 0xcb5914

    System pool was initialized

    Global pool was initialized

    pf_mem_init: Backup battery week = 38.


    Done executing startup script /hd0a/bin/mc.bat

    Status -1 from loadComputer


    21-09-24 09:18:14 MC0: iomgr_remote.c 2729 IoMgrRemoteInit: Can't open the Car2


    Status -1 from invoke IoMgrRemoteInit




    Looks somewhat promising but the teach pendant still sits there counting up.


    Any idea what I should do next?


    It's worth noting that the MC Console port is plugged into a 3HAC030439 remote access unit that I assume ABB used to dial in. Im un plugging it and plugging into my usb to serial which seems to work ok.


    Thanks

    Yes I entered the xdelete command and got a response. I wish I copied it now but it said something similar to your manual but not exactly the same.


    I then entered the reboot command and the controller would then reboot and I got the above response but the teach pendant still stayed on the counting screen.

    As you check each DC voltage, switch the DMM to AC mV and make sure there is less than 30mV of AC component (ripple). A higher AC component indicates weak components (usually capacitors) in the power supply. This works for ABB S2 > S4C+ low voltage DC supplies.

    Hi All, finally getting back to this. Checked the power supplies and everything looks ok.


    I connected again with hyperterminal and this time copied the response from the controller.


    I started with the xdelete “image.bin” and got response:

    -> xdelete "image.bin"

    xdelete "image.bin"

    deleting file image.bin

    value = -1 = 0xffffffff = _end + 0xffc65717

    -> reboot

    reboot

    0xcb34b4 (tShell): /hd0a unmounted.



    It would then rebook like this:


    AMIBIOS (C)1997 American Megatrends Inc.,

    Motorola Corp. PCI/ISA 98-W4037D08C

    AMIBIOS (C)1997 American Megatrends Inc.,

    Motorola Corp. PCI/ISA 98-W4037D08C


    /// Bootloader 1.1/8 Nov 24 1999, 00:20:32 ///


    disk 0:0 ATA STI Flash 6.1.0

    disk 0:1 unknown type



    done.

    system: '/hd0a'

    release: '/hd0a'

    Loading module /hd0a/bin/mc 1608728 + 60144 + 1028576

    Loaded configuration /hd0a/mc.cfg

    Starting at 0x108000...



    Starting RTC synchronization of system time...


    And then would loop like this seemingly forever…


    I then did a few reboots and it would do the same thing until I powered it down and removed all of the cables going to the computer and powered it back up again.



    I then booted it back up again and was back to the infinity counting up screen and following LEDs:

    CPU

    PWR: Green

    HDD: Nothing

    Status: Flashing green


    Just like before. We have the boot disc so I said I would try to delete the system and do a cold boot. I used the xdelete “system” and got the following response on startup:


    /// Bootloader 1.1/8 Nov 24 1999, 00:20:32 ///


    disk 0:0 ATA STI Flash 6.1.0

    disk 0:1 unknown type



    done.

    system: '/hd0a'

    release: '/hd0a'

    Loading module /hd0a/bin/mc 1608728 + 60144 + 1028576

    Loaded configuration /hd0a/mc.cfg

    Starting at 0x108000...



    Starting RTC synchronization of system time...


    /hd0a/ - Volume is OK

    Phys mem : 0x1fff000

    Perm pool : 0xa00000 @ 0x15ff000

    LocalCA mem : 0x18000 @ 0x88000

    LocalSM mem : 0x8000 @ 0x80000

    Local mem : 0x15ff000.

    BSP version : 1.1/15

    Creation date: May 19 2005 02:55:55

    Main network : fei0 100.100.100.14 00:01:af:0a:cf:dd



    Executing startup script /hd0a/bin/mc.bat ...

    mRouteAdd "192.168.125.64","192.168.125.2",0xffffffe0,0,0

    value = 0 = 0x0

    sp root_entry,"bin/install.cmd"

    task spawned: id = 0xcd4d84, name = t1

    value = 13454724 = 0xcd4d84

    System pool was initialized

    Global pool was initialized

    pf_mem_init: Backup battery week = 4.


    Done executing startup script /hd0a/bin/mc.bat

    Status -1 from loadComputer


    22-02-04 16:31:42 MC0: iomgr_remote.c 2729 IoMgrRemoteInit: Can't open the Car2


    Status -1 from invoke IoMgrRemoteInit

    ->




    It still didn’t enter the boot menu on start up, teach pendant never leave the count up window. It’s worth noting that we also tried a new teach pendant which had now effect.


    See full hyperterminal Log although I believe it may be missing the command where I deleted the system but everything this else is there.


    I assume at this stage we would be looking at replacing hardware. Anyone have any idea? Main computer? Hard drive? IO computer?



    Any help much appreciated. Thanks

    If there's no system, you should get the start window on the pendant.

    If you're going to hardware troubleshoot, the communication to the pendant comes from the I/O Computer thru the Panel Unit. The issue with the IoMgrRemoteInit also seems like it could be the I/O Computer.


    Once you do get the Start window, Lemster68 already uploaded the manual that explains the process >here<.

    Hi Skooter,

    That was my thought process, force it into the boot menu where you can select where to get the system from, but it never appears.


    I was of the same opinion with the IO computer and I have new one so I’ll try that first. I was also thinking of getting the compact flash adapter and replacing that although the text from hyper terminal indicates that the hard drive is ok.


    I’ll try the IO computer first and see how I get on. Thanks

    There are several I/O computers, the DSQC532A was the latest. I have gone backwards to the DSQC522 and had it work.

    The panel unit has some circuit protection for the comm signals - something to think about if the I/O computer doesn't fix.

    Hate to mention it but I've had the XS20 connector bad several times, the XS20-X7 wiring pinched, and XS20-X7 wiring cut :astonished_face:.

    Do you happen to know what software revision it has/had?

    Skooter,


    Thanks for the pointers, I’ll check those points out if the io computer doesn’t solve it.


    Still haven’t gotten back to this so no more news yet.


    It’s system pack 4-2.21. Thinking of upgrading to 2.27 while I’m at it.

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