Constantly rebooting the E43 controller

    Hello everyone!

    I have encountered a problem with constant rebooting of the E43 controller with the ZD250S robot. I will describe the situation in more detail.

    The problem started suddenly a couple of days ago. The robot was working properly, when suddenly it just turned off and started rebooting constantly. That is, it starts to turn on and immediately turns off. I will say right away that the X9 connector on the 1TR board has factory jumpers.

    Just in case, I decided to blow out the dust from the controller and the following happened: the controller turned on, worked for about 5 minutes and immediately turned off. And again the reboot situation repeated itself. After repeated blowing, nothing changed.

    I tried to pull out the I / O and Fieldbus boards, leaving only 1VA and 1TR, but this did not help. The power supply voltage is normal.

    I suspect a malfunction in the 1TR board. There is a second controller from which I can try to re-plug the board, but since this is a controller in production, I am afraid that I can damage the board.

    The strangest thing is that it still worked for 5 minutes after blowing.

    What else can be checked and what is the potential problem it can be?

    I only have an old backup of the robot, but if necessary, I will post it.

    AVR is intelligent device and if any output has overload detected, then AVR goes into current limit for small period of time, if time exceeds, then AVR will automatically turn off.
    If 1TR X9 pin 3 - 4 linked, then AVR will restart.
    In your case you are seeing power cycling effect.

    You will always carry small risk in damaging boards when using other controller, including self inflicted damage during transfer between controllers with ESD or dropping the board etc.

    I think you will have no problem with board transfer to assist in diagnosis (but it is your call).
    I have never experienced 1TR board causing this problem, but this does not mean possible.

    However, please check the following fundamentals first:
    - incoming supply to controller transformer present and 3 phases present and balanced in spec.
    - secondary output of transformer are correct and within spec.
    - look for CP2 MCB (mech trip in cabinet) is not dirty or degraded.
    - internal harnesses are secured including board insertion and backplane connections.
    - connection to AVR is secure on X201 and measure supply voltage is correct and in spec.
    - exchange teach pendant to eliminate.
    - exchange AVR to eliminate.
    - exchange MC unit to eliminate.
    - exchange 1TR to eliminate.
    - exchange power block with 1TB to eliminate.
    - check fans, disconnect momentarily to eliminate.

    If all above appear ok, then populate controller as normal and:
    - ensure encoder batteries are sufficient charged.
    - disconnect all umbilical's at controller side to robot arm.
    - disconnect all/any external services to EOAT which are connected at controller side.
    - power back up.

    If AVR maintains power, then field side umbilical or external services to EOAT are the problem.
    You will then need to troubleshoot further:
    - umbilical's for damage.
    - external services for damage.
    - robot arm internal harnessing for damage.

    From experience with these errors I have found:
    - missing or low supply/imbalance to incoming phases to controller.
    - AVR has aged and internal capacitors are damaged or internal circuit failure.
    - Umbilical or external services to EOAT or internal robot arm harness damage.

    Thanks, kwakisaki I will be near robot on Friday and try everything you recommended.

    I will add that I've already tried to turn on the controller without robot cables and without Teach Pendant. Also, another robot is on E01 controller, so I will be able to exchange (according to parts number in parts catalog) only 1VA and 1TR

    You say that it's possibly be AVR, but in parts catalog for E43 it's 50630-1162 and for E01 it's 50630-0033. I know that sometimes modules with different parts number can be exchanged, but if you know something about this case, tell me, please :smiling_face:

    Quote from dm.bogachev

    another robot is on E01 controller

    This does not contain same MC Unit or Power block, so these are not transferable and therefore cannot be proven/eliminated.

    AFAIK servo board (1TB) is same though but with dipswitch differences perhaps.

    AFAIK the backplane (1VZ) in E43 and E01 are the same, therefore card rack boards should be 100% transferable.

    AFAIK the AVR are also the same and can be transferred as they have same specification, but I have never done it.

    I have never swapped parts between 2 different controllers, so cannot give 100% assurance of compatibility, the above information is based on information I have and not experience.

    It is your call really........:icon_rolleyes:

    Hi again!

    I solved the problem. It was problem with the 1TR board. I replaced it and the robot started working fine. I couldn't find any visible damage on the broken board, but there are a lot of SMD components, so I can't pinpoint the exact fault on the board.

    Anyway, big thanks for the advises!

    Quote from dm.bogachev

    I solved the problem. It was problem with the 1TR board.

    Excellent, well done for finding the problem and feeding back your results......:top:
    That's one for my little black book, my first for hearing of 1TR causing this problem.

    It is likely to be a component that is short circuit and pulling one of the low voltage supplies down from the AVR, so if you have access to a circuit board repair specialist, then I expect they will be able to repair it too.

    Nice work my friend......:top:

    Smart thinking regarding the error logs.....:top:

    In your initial post regarding an improvement after a blowout, crossed my mind whether temperature monitoring errors were being generated after x period and to inspect the error logs for any occurrences but I dismissed posting this as I've never come across temperature errors creating power cycling events and it may be fruitless looking into error logs for this event you were experiencing.

    That's interesting though with the error code D1560.
    That leads to a nice - AVR, 1TR exchange suggestion (excluding harness short circuits).
    Also it is eluding to the 24v line being low which 1TR board utilizes heavily.

    Many thanks for the additional information, very beneficial to know regarding power cycling events and error to lookout for.......:top:

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