Posts by Skooter

Assuming you've checked common issues like incoming 3-ph, controller & robot connections, robot-to-controller cables, robot wire harness ...

Also, assuming this is a 2400/16 or /10. Can you jog A5 only or A6 only in joint? Use the joystick lock if needed. Can you further isolate it a single axis? Is there any movement at all on the upper axes when trying to jog them?

Not to say this is the problem but I've seen similar symptoms with an open motor phase or a motor phase arcing/leaking to ground but not fully shorted.

Based on your pics, this is an S4C+ controller with RW4.0. The RW2.1 manuals previously recommended were for 2 generations older S4.

This is the ArcWare 4.0 manual you need > ArcWare 4.0 and ArcWare Plus User's Guides

Which BaseWare is running?

Do you have the User's Guide? The guide for BW2.1 can be found here > BaseWare 2.1 Rapid Reference Manual & User's Guide
Look at ArcWare in the ProcessWare section to explain what is available regarding settings and how they work.

Ensure equipment is right as jarm alluded to: ensure the feeder rolls stop and not 'coast' when feed ends. Start with a new liner and make sure rolls, guides, liner & tip are properly sized.

Concentrate on getting great welds and then try introducing a small amount of burnback if the wire is too long.

This thread is for IRC5 manuals related to external / additional axis & axes.

Additional Axes Application Manuals for many versions of IRC5 RW5 & RW6. This covers most controller and RobotWare variations.

Don't delete the Base module, simply remove the duplicate Speed V-Sets from your program module.

The DSQC619 designation is generic for the IRC5 Additional Drive Unit (ADU) for the System 04 & 06 drives (black plastic). Here are the numbers for all 4 DSQC619 drives:

3HAC14550-1 is ADU 1C
3HAC14550-2 is ADU 1T
3HAC14550-3 is ADU 1U
3HAC14550-4 is ADU 1W (used with 6600/7600 controller)

Since you mentioned the -4, do you have an IRB6600 or 7600 controller?

Motor Unit (MU) 10, 20 & 30 were off the shelf motors ABB sold at the time for integrators to build with. They came out with a newer set - MU100 - 400 after that. You can use many different motors but I've found it easier to use an ABB MU or one pulled from a used robot as these are easier to setup.

I can upload some manuals to help explain if you need them.

Deleting modules is not always the answer. My guess is everything was fine before you reloaded the backup unless it was previously updated from a version below revision 113.

What is the detail of the current ambiguous error?

Consider making a backup as it is right now, then zip & post it for all to hunt for the issue.

Yes, you stated that before. Again, please provide voltages at A1 & A2 of each contactor while ON and while OFF. This will define which of the two run-chains is having an issue.

If you provide the voltages in post #10 above, we can narrow the problem.

Quote from rmyd027

Checking the tip dress position again after about half my caps life and now my position is 5~6mm off the dressing blade which can explain my poor cut.

Assuming 5~6mm we are referencing is distance of the fixed tip to the cutting blade?
Is it further away due to material removed from tip or movement of the tip away from the dress position?

OK - no backup. This still could be hardware or software.

Is there any place nearby that can check to see if the teach pendant is working?

It is the not to exceed pressure at the grease gun nozzle tip going into the robot cavity.

Manual for R-2000iC states gun tip pressure at 0.15MPa (22psi) or less for all cavities.

Verify nothing loose or worn on the gun and if it has mechanical compensation, that it is set & working correctly.

Yes - replace them with the power ON.
Motoman part # for the (2) MRC batteries are 479348-1 (Yaskawa # ER6C3)
Motoman part # for the K6 battery is 479348-2 (Yaskawa # HW8471030-A)

Changing MRC controller batteries can be found in the MRC Service Manual located in this thread > MRC

The K6 manuals can be found in this thread > MRC K-series robot manuals

K60, K100, K120, K150

K30

K10

This thread is for old MRC K-series. Hope this helps those trying to keep them running.

K3 & K6

Rather than starting new thread, added MRC controller manuals here.

Many times, we mount pendants next to the doors, in pendant lock boxes, etc. We usually fab hangers with 2.5" wide of 1/16 or 3/32" steel with 2 approx. 90 deg. bends. Round the corners & edges where the pendant handle contacts and finish with paint. They're not fancy but they are sturdy.