A second DSQC313 will work for the 7th axis. Make sure the serial data out (SDO) of the robot SMB goes to the serial data in (SDI) of the external axis SMB.
You should be able to use some of the wiring from the 1500 cabinet as the S3 & S4 drive circuitry is similar.
The DSQC236C will go in the rightmost (AP7) slot in the drive rack.
The External Axis 4.0 manual in your link is for S4C+. The M94A IRB1400 Product Manual has much of the information you need.
Are you getting any other alarms besides the SRVO-050? Check the history [F3] in the alarm menu.
Some ideas to check:
Check the all connections regarding axis J3, could be dropping due to a missing phase if it happens as soon as the brakes release. This is common when the RM1 connector at the base of the robot is not fully seated.
If it takes a few seconds before the it alarms, the brake may not be releasing and as the robot tries to hold position, it starts to fight the brake and eventually alarms. It might drop slightly due to some weakness in the brake.
A short cut to a Cold Start is to hold in/down the Fault Reset when powering up until it mentions cold start on the TP screen during boot up.
From the picture, it appears wires A & B are the CAN bus serial communication lines used for ArcLink serial communication between the robot controller and Lincoln power sources.
The only way I've changed R-J3iB from Lincoln to Fronius is to use the Fronius ROB5000 interface and having the Fronius Equipment software option installed in the robot controller. The controller needed to have ArcTool V6.40 software to use the option.
See if the seller will exchange the arm for another. If not:
Lay the robot on its side (so the grease doesn't pour out), pull axis 2 motor and verify it works outside of the robot. I've seen bad motor bearings act similarly and just because the brakes measure good and give a mechanical sound does not mean it is mechanically disengaging.
When the motor is pulled, you can assess the grease and the wave generator. If the grease is black and runny, it is not a good sign. If you clean the wave generator, you need to lube it to get a good feel for wear as even a new one will feel 'rough' without being lubed. The teeth on the flexspline should still have a little bit of a flat at the top and not be worn till they're pointed. Seen flexsplines damaged by collision and shipping damage where the flexspline is twisted somewhat and causing issues.
The DSQC504 is the Base Connection Unit in the S4C+ controller. Not sure what connections you are referring to. The robot should boot from a previous image stored on the hard drive. Are there error messages on the teach pendant?
You should not have to do any reconfiguration and there is no default to return to. If the arm is the same as before, it should be already set for the 2-axis brake.
At CN6-A2 to -A7 for axis 2, you should measure 100 - 110VDC when the brakes first release. The voltage will then drop to half (50 - 55VDC) after a short period of time. The lower voltage still maintains the brake release and now using half the current. The 53VDC you measured is normal. You should get the same voltage readings for axis 3, CN6-B2 to -B7.
Haven't worked on one in many years but still have the manuals to share.
A & AD Error Codes
In a quiet environment, you should hear a click sound near the motors when the 2 brakes release when you first try to jog the robot.
Brakes are 90VDC and should measure approximately 1K-1.2K for these small motors.
Brake connections to the robot base are:
CN6-A2 > RM-3 > J2 BK+
CN6-B2 > RM-11 > J3 BK-
CN6-B7 > RM-4 > J3 BK+
CN6-A7 > RM-10 > J2 BK-
To manually check brakes, I use a 60VDC power supply to release Fanuc 90V brakes and it works great every time. Just make sure to secure the robot first.
At CN6, brake connections are:
If the motor seems to run good outside the robot, look at the harmonic drive. Sometimes the bearing-based wave generator will wear enough to cause vibration and give collision alarms. Make sure the correct grease is used. Don't have the 200i manual available where I'm at but the 100i and the 200iB both use Harmonic Grease SK-3.
Harmonic drives used in many robots are made by Harmonic Drive LLC. A good video to see is at
.I might have more specific help but I need the entire part # of the FD235HFxxxx disk drive.
You want the Drive Select (DS) to be 0 and the pin 34 output to be 'Ready' not 'Disk Change' (DC).
Regarding the position update speed on the teach pendant - Have you swapped pendants? It may be a stretch, but a difference in TP firmware might effect the position screen update rate. Is the controller software in both robots exactly the same?
Regarding the DTERR alarm as it is currently - Are there any other alarms related to the SRVO-068 in the history before or when the alarm occurs? On which axes is the DTERR occurring?
Looks like an M98A to me.
If the motor is still running hot, the PulseCoder may be the issue. The constant high heat causes some to be more susceptible to noise after a while.
Have you tried swapping the entire motor to see if the heating issue resolves?
If it is a noise issue on the data lines as the reply you received from Fanuc stated, I would still be looking at the shielding being grounded at the right spots.
Can you power the R-J2 back up and verify the I/O setup and if system variable $IOMASTER was set to 'True'?
The LR HandlingTool Operator Manual for each controller would be very helpful.
Pinout - haven't built one in many, many years - the ones I purchase are easier. But the picture on the right seems like the ones I did build.
Which port - Use the default port on the SOP (outside).
Initialize port - No need to initiate. It is default for the PS100 Floppy Unit which makes it right for Kfloppy.
Set device - Just select Floppy from the 'Select device' screen.
USB-to-serial adapter - The COM port number depends on which USB port you use. I go to Device Manager after plugging in the adapter to see what COM port it is and then change to that port in the Kfloppy Port Settings. For fun, move to another port and see what the change is.
Other stuff - Make sure no other program is trying to use the COM you select. I shut down RSLinks on my XP laptop before opening Kfloppy.
Other Windows - Besides XP, I've had success with Win7 laptop running DOSBox with USB-to-serial and Win10 laptop running DOSBox with built in serial port and USB-to-serial.
If you mean the Molywhite Re.00 grease, it's good you brought that up. Please be aware that ABB put out a memo back in 2000 stating "Molywhite RE00 is no longer approved for ABB Robots." and to use the Optimol Longtime PD0. Please see the attachment.
Please reread the previous posts and try to provide as much information as you can about the controller boards, serial #, information from backups, etc. The 3 different software versions for the S4C have different requirements. An example: going backwards from RW3.2 to RW3.1 can cause issues on a Robot CPU board.
Make sure the 6-pin connector at the top of the bleeder unit is correctly plugged in. There isn't a lot of room and can be difficult to plug in especially if the male pins on the bleeder are bent. You can measure the bleeder resistors easily from the 4-pin X3 connector at the bottom front of the DC-Link (rectifier). It should be a between 10 & 15 ohms if I remember correctly. If the bleeder checks good, try changing the DC-Link.
The teach pendant issue may be separate, try another pendant to see if it makes a difference with the 20175 error.
Download the M96 IRB6400 manual in the manuals section and use that, it lubes exactly the same. Changes in the M98/98A 6400 gives slightly different volumes.
Castrol Optimol Longtime PD0 has a new name => Castrol Tribol GR 100-0 PD
Don't forget the large diameter bearing and the balancers.
