With just a slim chance and no guarantees - Try the attached.
I messed up by picking the wrong diskette, both are the same program numbers. If I provide the software to you can you get it to work, I will pay for the work you would need to do, I don't have the know how to get this done.
If you have the software, then you can easily do it. Are their ABB labels on the disks? If not, just sort all the disks by what is listed in the DISC.ID file on each disk and make a list. Post the list.
That makes it easier, no P-Start or ext. axis option disks.
There is a key disk that contains information about the software license associated with this key along with the encrypted key. There also is a generic RW3.2 package of 10 disks containing different variations of the software and most options.
Loading software procedure can be easy or challenging depending on the setup.
The guide found >here< has information for S4C RW3.0 but most of the information regarding software loading and backup is the same for RW3.2.
Please note once RW3.2 is loaded, you must NOT try to load versions 3.1 or 3.0. It will corrupt the DSQC373 Robot Computer Board.
You have a long arm 4400, is it arc welding? Are there positioners (ext. axis)?
Check the DSQC256A System board LEDs when you pull in the deadman and verify the 'GS' is LED is on.
The System board LEDs only monitor the 24V side of the dual run-chain, so if it's on, the problem is likely on the 0V side of the run-chain.
General Safeguard Stop is XT3-A5 to A6 for the 24V chain and XT3-B5 to B6 for the 0V chain.
S4 M94-M96 run-chain and other jumper connections at terminal XT3 in bottom left corner:
A: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12 (24V run-chain)
B: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12 (0V run-chain)
I see the issue with the software - the disks are from different software:
Disk 1(2) is from 3HAB2334-1 BaseWare OS RAP 2.1
Disk 2(2) is from 3HAB2333-1 BaseWare OS 2.1
Both disks need to be either 3HAB2333-1 or 3HAB2334-1. Can't mix them.
What does it look like compared to disk (1).
As mentioned dozens of times on this forum, please state which generation of RW software you are trying to load and the model of the controller.
Although this is slightly different software, the disk #2 DISC.ID file should look similar to this when viewed with a text editor:
With the disk set you're using, the difference between disk 1 and disk 2 should be the Boot disk number and the special characters at end of the file that represent the embedded encoding on the disk.
DO NOT try to edit this file as it will not effect the encoding and only confuse/misrepresent what is encoded on the disk.
Post what you find.
You don't say what version of software is being loaded.
Each disk in the S4 software disk package has a unique identity coded the DISC.ID file that includes the robot serial number that the software is licensed for. It gives this error if the current disk does match the encoded serial number of the previous disk.
Check the DISC.ID file on the disk giving the error and make sure it belongs with the software pack you are trying to load. You can view the nonencoded portion of the file by opening it with a text editor such as WordPad, Notepad, etc.
Glad to see you using HyperTerminal as a troubleshooting tool.
The attached is a compilation of TSB's and notes ABB put together for their service techs and the occasionally sent to others needing help.
It has very good instructions on loading S4 2.0, 2.1& 3.0 and S4C 3.0 software. It also has I-Start, S4 Backup & Rapid Converter notes.
This was requested by davsearle, but I made a separate thread to make sure it had an easy-to-find, descriptive title.
Hope it helps.
The TP checks the joystick when it powers up. If the joystick reads anything, then it disables the joystick and gives the error.
Possible no-cost remedies:
1. Make sure the joystick is centered and nothing is touching the joystick when it powers up.
2. Check the joystick rubber boot and make sure nothing is stuck in it and it is very clean (cotton swabs work good), has no wrinkles and the handle easily centers when released.
3. Remove the TP back cover and make sure the connector from the joystick is fully seated. Be very careful not to pinch any wires when reassembling.
Are the circuit breakers tripped?
Open the front door and see if the power supply AC OK LED is on. Should have 3-ph 55VAC going to the power supply.
If you move the robot to cal (zero) position then the rev counters will be at zero and motors at their offset point in the zero revolution. Comparing them with the fine calibration offsets stored in the parameters will give nearly identical numbers.
Like Lemster68 mentioned, store the original fine calibration numbers as data and then use a routine compare them to the current fine calibration offset parameters. This should let you know if anyone has recorded new fine calibration offsets without moving the robot.
Would be very surprised if someone on the forum hasn't done this already.
My preference after creating a new system using RobInstall is to then download it from the RobInstall menu.
I'm definitely not upset. Slightly annoyed that I gave a path to get the drive to work and it was dismissed but you get used to that here. Instead of ignoring, I tried to establish that I have experience with S2/S3 floppy drive conversions, gave a possible work around with a unit from GRP and where to gain more information.
A new system should help. She's a nice looking bot. Look at the manipulator internal cables and see if there's any cracking of the sheathing (very common on these). A light wrapping of electrical tape on any cracks will give your cable set a longer life. You should also consider starting with fresh battery packs in the robot and controller. When in the base of the robot looking at the battery pack, make sure the shielding of the resolver cables is tie wrapped to the metal 'railing' on the right side of the SMU mounting bracket. Having the resolver cable shielding ungrounded is somewhat common to see and leads to occasional resolver errors when enabling the motors.
According to datasheet, there is no need to change floppy disk drive electrical specifications since this LSI chip is fully compatible IBM even the write/read data over ABB is not DOS. I have no ideas how to proceed further
So the hundreds of new & used disk drives I converted to work in the S2/S3 robots wasn't necessary? The fun I could have had in the '90's given that time back. Perhaps you should consider just replacing the drive with the conversion from the great folks at SWEROB (Global robot Parts). If you want to learn more on the ABB floppy interface, get a good copy of an S2 product manual and read the theory of operation of the DSMC110 board. A DSQC215 processor board tells me the controller is M90 or M90A.