ABB IRB6400C start up problems

    Hi everyone! I have just bought an ABB IRB6400C M94A robot with S4 controller.

    I have tried to get it to work (manual jogging) but I have not got so far yet. The robot has been standing without power connected for a quite long time, so I suppose some data has been erased from the memory? Or has it, if it says Baseware OS 2.1 in the welcome menu?

    When I switch the main lever on, the controller starts up, and I get immidiately 20 error codes. I can press OK and then I get to the welcome menu. When I try to manually drive the motors with the joystick, I get "servots.c 760 not allowed if servo task not initialized OK" or error 20080 "Not allowed when asix is not commutated".

    I have measured the 3.6V batteries for the memory, and they seem to be okey (3,61V and 3,70V). The SMB 7.2V battery was only at 6,3V before starting, but after a while above 7,2V.

    Do I need to re-install the Baseware 2.1 or what should I do to continue the start up process? The floppy drive is replaced with a usb-memory reader. I cannot get to the calibration menu because of the error message. Do I need the original floppy drives with the original systems packs or some kind of usb-memory with the right data? Or could I just reboot the system? Set it to some factory settings?

    Thanks.

  • 95devils September 3, 2024 at 4:33 PM

    Approved the thread.

    No, I dont. The floppy disk reader is replaced by a usb-emulator. There is no usb-memory in the usb-emulator at the moment. Is there an internal memory in the usb emulator?

    It seems that the calibration offset values for the axis are still saved in the parameters in the controller menu.

    The problem now is that when I press the safety guard stop button on the controller, I get the "20080 axis not commutated" message. The software seems to be okey, but do I still need ti re-install it?

    I am not sure about the difference betweeen re-install, re-boot and re-load..

    No need to reinstall. In the parameters, all 6 motors must have a commutation value of 1.5078 and the 'Commutation Valid?' must be 'Yes'. Go back to top of parameter menu and select File drop down & then Restart to activate parameter change. Restart is also in the Service menu.

    Hi, thanks for your answer. i tried to commutate the axis, but at the first try i got the message "Commutation process started! ready in a few seconds...". After about 10 minutes I shut down the machine because nohing happened. Sometimes the error came up. " servots.c 760 Not allowed if.::" or the error: "20076 Not allowed in System Failure state.".

    In the commutate menu the Status for all axis is "Commutated". Is it fine then? i can not find the values 1.5078 anywhere? Neither the "Commutation Valid, yes."

    Any suggestions what to do?


    It is not fine. You are in the Service menu and are setting the commutation to the resolvers current position. This is overwriting the commutation parameters with the wrong information. This method is part of a procedure only for the S3 style IRB2400 & 3400, NOT the IRB6400.

    As stated in previous post, you need to go to Parameters menu. Topic is Manipulator, Type is Motor. You will have to select each motor which is labeled something like IRBx if I remember correct.
    You will be able to set the commutation to the required 1.5708 for each motor as previously stated.

    For parameter information, download the User's Guide BaseWare 2.1 in the manuals section of this forum and search commutation.

    Thanks for answering fast.

    I have now found the right menu and the values for the axis commutation.

    The all six axis had the right commutation value 1,5708, and all were chosen as Valid, yes.

    I can't still get it to work, or get any axis to move. Same error (20080 axis not commutated) occurs when pressing the safety guard switch button on the controller.

    What do you think I could try next?

    I haven't change the parameters, only checked that they are correct. But yes I restarded it also after the check. Didn't help.

    I am not sure has it had an external axis setup. Now there is no external axis connected to it. But not sure of an external axis is setup in the settings. Not sure how to figure that out.

    Physical signs of an external axis in an S4:
    > A drive in the 7th drive slot (far right) of the drive rack or if it is empty, wiring going to an orange connector in that slot.
    > A Serial Measurement Board (SMB) mounted in the cabinet.

    Might be harder to see in the parameters if you're inexperienced and my memory is not pulling up the key places for you to look. If you do a backup and post a copy of the MOC.cfg file, it will be easy to see there.

    S4 controllers that haven't been switched on for a long time often loose parts of the operating system, and throw many unrecoverable errors. Think you should install OS, therefore you need the complete set of installation disks.

    In first post you told, that controller throws 20 errors, but you mentioned only two of them, what are the others?

    Jm2c

    Quote from Skooter

    Physical signs of an external axis in an S4:
    > A drive in the 7th drive slot (far right) of the drive rack or if it is empty, wiring going to an orange connector in that slot.
    > A Serial Measurement Board (SMB) mounted in the cabinet.

    Might be harder to see in the parameters if you're inexperienced and my memory is not pulling up the key places for you to look. If you do a backup and post a copy of the MOC.cfg file, it will be easy to see there.

    I don't think I have an external 7th axis. Picture below:

    .

    I am wondering are these computer boards leds supposed to light red? I think these two to the left are for I/O:s,


    Quote from hermann

    S4 controllers that haven't been switched on for a long time often loose parts of the operating system, and throw many unrecoverable errors. Think you should install OS, therefore you need the complete set of installation disks.

    In first post you told, that controller throws 20 errors, but you mentioned only two of them, what are the others?

    Jm2c

    Sometimes there is 9 error codes at startup, sometimes 20. Below the 9 codes:

    Aren't these all coming because of one fail somewhere?

    hermanncalled it. A repeating 33202 & 31608 are usually unrecoverable. Hopefully reloading the RobotWare will fix it and you have the RobotWare and an old backup somewhere in the stuff that came with the robot.

    While you still have some functionality, I highly recommend setting up a USB floppy and verifying it works correctly. You will need it to load RobotWare.
    Be aware removing any of the (3) boards on the right will dump the software.

    Regarding the red LEDs on the (2) DSQC223 Digital I/O boards. The red LEDs turn off once the those boards are defined in the parameters. An old backup will likely have those boards and associated I/O defined.

    Quote from Skooter

    hermanncalled it. A repeating 33202 & 31608 are usually unrecoverable. Hopefully reloading the RobotWare will fix it and you have the RobotWare and an old backup somewhere in the stuff that came with the robot.

    While you still have some functionality, I highly recommend setting up a USB floppy and verifying it works correctly. You will need it to load RobotWare.
    Be aware removing any of the (3) boards on the right will dump the software.

    Regarding the red LEDs on the (2) DSQC223 Digital I/O boards. The red LEDs turn off once the those boards are defined in the parameters. An old backup will likely have those boards and associated I/O defined.

    Sorry for my amateurish questions, but is "reloading the RobotWare" same as re-installing the software/OS?

    The original floppy is replaced with an USB-reader. In the original floppy reader there is an old backup floppy I think.

    Can I re-load the RobotWare from a USB-memory with the USB-floppy reader, or does it has to be done by reading original floppys with the software?

    Another thing that isn't mentioned yet, I have a computer with Windows XP installed to the robot controller box. It has some files, and also a software named Robot Controller. Do you know if I could use this to control the robot? The computer is plugged to the robot I/O from the computer COM-port.

    Thanks for answering and helping me!

    Could be a version of an S4PC also known as a 'Tophat'. I don't remember WINXP running on one, only WIN95 or maybe WIN98. Sadly, all my info stayed with previous employer. Used to repair them 25+ yrs ago. It hard to remember the differences with the S3PC back then too.

    Is there a smallish 8-slot Radisys computer rack mounted up high on the back wall?

    Good news is this Tophat will likely have the RobotWare 2.1 operating system and backups.
    There may also be a folder with instructions and manuals.

    Quote from Skooter

    Could be a version of an S4PC also known as a 'Tophat'. I don't remember WINXP running on one, only WIN95 or maybe WIN98. Sadly, all my info stayed with previous employer. Used to repair them 25+ yrs ago. It hard to remember the differences with the S3PC back then too.

    Is there a smallish 8-slot Radisys computer rack mounted up high on the back wall?

    Good news is this Tophat will likely have the RobotWare 2.1 operating system and backups.
    There may also be a folder with instructions and manuals.

    Don't think there is a 8-slot Radisys computer rack.

    I also found a Terminal Emulator program on the computer and now trying to figure out if this is relevant for the connection to the robot.

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