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

Thanks Lemster, Laptops with a straight comm port are getting rarer. I’ll give the usb to serial a go and see.

Are there any alternative options no?

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.

Ok I’ll ask them to power it back on in the morning and see. Thanks 👍

Thanks Dave, I’ll check my power supply voltages and see. I didn’t think to do that when I saw the green LED. Thanks

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

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

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.