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  1. Robotforum - Support and discussion community for industrial robots and cobots
  2. Members
  3. Skooter

Posts by Skooter

  • ABB IRB 2400 IRC5 2004 Event Message 39405 " Maximum PWN Reached in Torque Controller"

    • Skooter
    • July 12, 2025 at 12:27 AM

    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.

  • ABB S4 Wire Stick out

    • Skooter
    • July 11, 2025 at 1:26 AM

    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

  • ABB S4 Wire Stick out

    • Skooter
    • July 10, 2025 at 4:49 PM

    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.

  • IRC5 External / Additional Axis Manuals

    • Skooter
    • July 9, 2025 at 4:37 PM

    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.

    Files

    Application Manual 6.0 - Additional Axes & Stand Alone Controller 3HAC051016-001 Rev-.pdf 3.86 MB – 6 Downloads Application Manual 5.15 - Additional Axes & Stand Alone Controller 3HAC021395-001 RevP.pdf 4.68 MB – 5 Downloads Application Manual 5.13 - Additional Axes & Stand Alone Controller 3HAC021395-001 RevL.pdf 3.84 MB – 7 Downloads Application Manual 5.0 - Additional Axes & Stand Alone Controller 3HAC021395-001 RevG.pdf 3.76 MB – 9 Downloads
  • Ambiguous tool0

    • Skooter
    • July 9, 2025 at 4:36 AM

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

  • Additional axis/servo for IRC5 M2004

    • Skooter
    • July 9, 2025 at 3:32 AM

    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.

  • Ambiguous tool0

    • Skooter
    • July 9, 2025 at 2:06 AM

    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.

  • 39103 Drive System Error

    • Skooter
    • July 7, 2025 at 9:06 PM

    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.

  • 39103 Drive System Error

    • Skooter
    • July 3, 2025 at 10:56 PM

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

  • Tip Wear compensation

    • Skooter
    • July 3, 2025 at 9:36 PM
    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?

  • Abb IRB 2400 (Teach pendant connexion lost)

    • Skooter
    • July 3, 2025 at 9:23 PM

    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?

  • fanuc Grease Quesitons

    • Skooter
    • July 1, 2025 at 10:59 PM

    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.

  • Tip Wear compensation

    • Skooter
    • July 1, 2025 at 10:37 PM

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

  • Batteries replacement on old Yaskawa MRC séries

    • Skooter
    • July 1, 2025 at 1:47 AM

    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

  • MRC K-series robot manuals

    • Skooter
    • July 1, 2025 at 1:31 AM

    K60, K100, K120, K150

    Files

    MRC K100, K120, K150 Manipulator Manual 132330-16.pdf 13.83 MB – 1 Download MRC K60A, K60C Manipulator Manual 132330-3.pdf 3.29 MB – 1 Download MRC K60 Manipulator Manual 132330-13.pdf 1.22 MB – 1 Download
  • MRC K-series robot manuals

    • Skooter
    • July 1, 2025 at 1:30 AM

    K30

    Files

    MRC K30 Service Manual.pdf 708.36 kB – 1 Download MRC K30 Manipulator Manual 132330-10.pdf 29.45 MB – 1 Download
  • MRC K-series robot manuals

    • Skooter
    • July 1, 2025 at 1:28 AM

    K10

    Files

    MRC K10A Manipulator Manual 132330-8.pdf 2.08 MB – 1 Download MRC K10M Manipulator Manual 132330-9.pdf 16.52 MB – 1 Download MRC K10 Service Manual.pdf 682.4 kB – 1 Download
  • MRC K-series robot manuals

    • Skooter
    • July 1, 2025 at 1:25 AM

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

    K3 & K6

    Files

    MRC K6 Service Manual.pdf 633.63 kB – 2 Downloads MRC K6 Manipulator Manual 132330-4.pdf 3.14 MB – 1 Download MRC K6 Dual Arm Manipulator Manual 132330-5.pdf 5.97 MB – 1 Download MRC K3S Instruction Manual.pdf 3.19 MB – 1 Download MRC K3 Manipulator Manual 132330-1.pdf 2.87 MB – 21 Downloads
  • MRC

    • Skooter
    • July 1, 2025 at 1:16 AM

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

    Files

    MRC Alarm & Error Codes 99-06-04.pdf 356.06 kB – 1 Download MRC I-O Boards Installation & Setup Manual.pdf 214.27 kB – 1 Download MRC Troubleshooting Guide Ver.3.144B.pdf 1.32 MB – 1 Download MRC Service Manual.pdf 631.66 kB – 1 Download
  • Pendant Mounting Solutions

    • Skooter
    • July 1, 2025 at 12:43 AM

    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.

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