CR-E116 "0531" alarm

Quote from kwakisaki

Have you spoken to Mitsubishi about your issues and questions?

I've made an inquiry a few weeks ago, but have not yet received a response. I've sent emails out to a few distributors that offer repair services as well. Only one replied, but I'm still waiting for a follow up after providing them with more details.

All of the surface mount electrolytics have been replaced and I can now get the brakes to release under the Z-phase menu. Additionally, the CPU has been swapped with a known working one, although with no noticeable improvement. My issue at the moment is that the controller sometimes hangs on startup displaying either "c." or "8.". Holding down the stop and reset buttons on restart does nothing.

The fail/run LED on the main board being dimmly lit (seen in one of the screenshots in a prior post) has me under the impression that there might be some contention somewhere. The nearby control logic seems to be functioning with nothing held high or low.

I'm not sure what's going on now. I was getting some life out of it, but now it hangs every restart and is stuck displaying "8.". I am allowing for a cool-down period to discharge the caps as recommended in the manual.

So far, about 80% of the controller has been recapped. The legs of the two LF398's had some damage from nearby cap leakage and have been replaced and socketed (I had working spares). All of the connectors have been inspected and pins were replaced if they showed signs of damage. I reflowed the pins for the connectors on all of the boards and tested for continuity. Unfortunately, all of this made no change and the issue from the prior post still remains. I'm fairly convinced at this point that the firmware for the controller is indeed relegated to the eproms and that the eproms need to be reburned. Finding someone with a working controller willing to dump the contents is going to be difficult.

Edit: Still no reply from any of the Mitsubishi service outlets that were contacted a few weeks back.

I ripped the contents of the two eproms if anyone wants to help verify that the data is still valid.

CRE116.zip

I just noticed that one side of a 74hc74 has both outputs low. Touching the probe to either output seems to temporarily clear some of the contention issues, so this chip will be replaced. The coating on these boards have made troubleshooting a nightmare. The boards being populated on both sides and having a large internal ground layer has also made part replacement an ordeal.

Does anyone know of any alternative controllers for the RV-E2/RV-E3j robots?

Does anyone have a replacement E31CPU for sale? The only example I found of one available online has various missing capacitors (according to the images in the listing). Even though it is listed as working, I'm hesitant to spend $1,500+ to have something shipped from overseas without absolute buyer protection.

Would there be compatibility issues by using a replacement E31CPU board? Would any of the custom ICs need to be swapped? I'm really banging my head trying to get this arm working and was hoping someone would have chimed in by now with even a potential controller alternative.

Would the CR1-571 be a possible alternative to the CR-E116? Regarding the arms themselves, I'm not sure how much the RV-E2 and the RV-2A differ electronically other than the harness.

I'm currently getting a "0531" (amplifier/encoder not connected) error code. Nothing obvious with the physical connections and everything meters fine. Any ideas?

Tested each individual pin on both cables and found no issues. There was a blown 1.6A fuse on the E332ME (E*32ME) board, but no difference was made once it was replaced.

Edit: The "0531" alarm occurs even when disconnected from the RV-E2 arm.

I'm assuming the problem is with one of the E321AM1 boards, but this would be a recent failure as they were all working before. I also noticed that when attempting to set the Z-phase that nothing registers in the Z-PHS row on the pendant when manually moving the axis after having reset them.

Not having schematics and pinout diagrams is making this issue difficult to track.

Does anyone know if the 0531 alarm originates from a communication error within the controller or from the actual robot?

Still no progress. I noticed the majority of those knowledgeable with this model are over on the European version of this site... which might explain why this thread is still active.

What does the top red LED by the large caps indicate?

It seems the relays on the E31P4 board are not switching (possibly why the LED is out). I'm not sure if this is what's causing the E321AM1 board issues as I was at one point earlier in this thread able to detect encoder movement.

Three-month anniversary.