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Posts by Robodoc

    I hate to say, but you went through hell because of a simple problem.


    The "serial I/O communication" alarm/message is because the robot has a serial I/O card, most likely a MARIO card, that talk to a PLC. If the PLC communication stops, you get this alarm/message. You can go to a universal output and tell the robot not to worry about the PLC communication and go on.


    If you don't have a PLC you can remove the card and not have to worry about the alarm/message any more.


    When you change processors on an MRC there is a procedure you need to follow. The first thing is to do a full backup. Never, never, never do the command "initialize the MIF01". If you do this you must reload the CMOS batch file from the robot or initialize the whole robot.


    To back up an MRC you need FDE for Windows and a PC with a RS232 port (or usb to rs232).

    As part of the startup diagnoses if the robot does not find something it must have (like the pendant) it just stops and does not complete the process and therefore does not turn on the power to some components. You must have a pendant.


    If you too have the 24 volt power supply alarm you have to find what is pulling the 24 volts to zero. This can be the pendant, pendant cable, MSP02 card (the one on the playback box), any I/O connected to the robot, the MRY01B card, the I/O rack, the MIF01 card, basically anything that is 24 volts.

    The gate switch is dual channel. The two contacts for the gate input must come on at the same time. Is the gate switch connected directly to the robot or is the gate switch connected to a PLC or Safety PLC.


    If it's connected to a PLC, the outputs from the PLC may not be coming on at the same time.


    If it's connected directly to the robot, check the connections on the gate switch.

    Yes, there are a bunch of things that can contribute to this.


    If your robot is an MRC, there are capacitors in the encoders that go bad over time and drain the battery. Also on the MRC there are two sets of wires for the battery at the base of the robot. The idea is to plug a new battery into on set then remove the old set. The now spare set "should" be taped up to keep shit out of the contacts. Some people feel the best way to keep the shit out is to plug the two spare wire into each other. This kills the battery. Lastly in MRC there are two battery boards in the main rack. These boards go bad and give a false weak battery alarm.


    In NX100 and beyond, the battery at the base of the robot plugs into the battery board. This battery board can go bad. If the base of the robot is full of water you can kill the battery board.


    With all robots, you can have a harness going bad or an encoder going bad.

    Do not format any card to be used in a robot with Windows. Windows will make the card NTFS and Yaskawa robots do not know what that is.


    No you can not format with the DX controller.

    Okay, now that we know the whole story, try this.


    Put your 128meg card in a PC and do these commands;


    1. Open a command Window (Windows+r > cmd)
    1. diskpart
      A new window will open up with a “diskpart>” prompt
    2. list disk
    3. select disk n (where n is the number of your CF card)
    4. Clean all (this completely re-formats the disk – it will take a while and appear to hang but be patient)
    5. create partition primary size=32
    6. Select partition 1
    7. Active
    8. format fs=fat
    9. Assign
    10. Exit

    Your 128meg card is now 32meg. You will have to format it in a camera. If it still does not work the CF card you have is uncompatable with the XRC controller.

    You need an old camera that takes CF cards. Format it in the camera and the XRC will work.


    Please remember most XRC robots only take up to a 32meg size. Some will take up to 64meg, but nothing higher.

    This alarm comes from the ABSO data. Back in the day, Yaskawa tried "resolvers" rather than encoders, however, they found resolvers unreliable and went back to encoders. The "replacing RD board" has to do with resolver data that does not exist in MRC robots.


    When you have this alarm, some or part of your ABSO data has been lost (even though there are still numbers in the calibration page). The only way to resolve this alarm is to calibrate all axis. If you go to the Home calibration page and write the numbers down, calibrate all axis, then manually put the nubers back you should be okay.

    Like a car you should take it all apart, sand blast and grind it down, prime and paint.


    You can knock the loose stuff off and paint over the crap, however, the flaking paint will continue to flake and take the new paint with it. Just like a cheep paint job on a car.


    Both Yaskawa Canada and Yaskawa America have rebuild departments. You can send your robot to them to be painted or they both offer core exchange programs. Call your local Yaskawa rep to see what they have to offer.