Posts by Skooter

Regarding the software - I would copy the disks to make sure they copy with no errors. Post what the labels say and someone should be able to tell if you have what you need. Hopefully one disk is a backup disk - you might need that to get the commutation numbers listed in the MOC.cfg file if someone changed motor or resolver and didn't update the label under the side cover.

Batteries - During bootup, the controller checks the voltage of the batteries. This is a warning and does not effect booting. It is an indicator that battery voltage may have gotten low enough to effect the memory.

Also consider Fanuc may not like the Image of software from one robot system to be put on another with regards to licensing.

Have you triple checked the current robot is exactly the same as the one the Image came from as suggested by HawkME? The A05B-1329-Bxxx part number on the robots ID plate should be the same. Different wrist flanges than specified can effect TCP.

I see a lot of programmable SMC units and current customer uses lots of the these so my guess is they must be inexpensive. This is a clean environment so if your installation is challenging, you may want to look at the other brands that may be more robust. SMC makes different versions besides the one in the attached pic. Numatics & Festo mentioned by HawkME have good reputations.

and if mastering looks great (not just ok), I'll use a long straight edge and move the robot along it to make sure it moves correctly. I choose an unused TCP, jog in World coordinates and set the straight edge up to match World X or Y. If it jogs straight then I program a linear move across the length and verify again. It helps to verify motion when I'm having a bad TCP day.

Using programming, that would be my first suggestion. If it only occurs on certain moves is to add a point at a lower velocity along the beginning of the path to allow the play to be taken up at a lower speed before accelerating. I've done both to keep production going while waiting for parts (mostly Fanuc).

Mechanically, I would first grease the large diameter bearing. I seen many 6400s where they were neglected and causing drag. Grease it slowly at both grease ports while someone carefully jogs the robot slowly thru the entire axis 1 range several times. Watch for fresh grease (EP-2) to come out from under the grease seal while it jogs. Two 90 deg grease fittings are needed if the plugs are still in.

I/O issue? Maybe a system signal assignment needs to be "MotOnStart" instead of "Start"

Tend has something similar to ZDT that works with many different robots. https://tend.ai/

Which controller?

Did you try the power supply? Change the whole servo servo amp.

The fiber optic transceiver on the axis control board does not operate much under 4.75VDC.

I've had this issue where the servo amp power board (lower section) was loading the 5V enough to drop the voltage just under the 4.75 needed by the fiber transceiver. I started with the power supply and then the servo amp control board but still had 4.7-4.8 volts to the transceiver. Changing the entire servo amp fixed it.

Axis 1 uses a large RV reducer for gear reduction and a very large diameter bearing for support. Neither one has any adjustment. Both require removal of the robot (1600kg) from its base to replace and are very expensive.

Check to see if there is a difference in play between having the brakes engaged and with the servo motors engaged (hold the deadman in and bump the joystick).

The M96 IRB6400 Product Manual found >HERE< will give you guidance.

I was told years ago that V6.40 was a rewrite and more in common with V7 than the earlier versions of V6. This was the reason a different version of OLPC was needed for V6.40 than for V6.22.

In addition to Lemster68 recommends:

Could be the axis brake not wanting to release the first time. Weak spring(s) on one side, excessive dust and/or uneven shaft wear can cause binding.

Make sure axis 2 has the recommended level of lubricant.

Could be a dirty contactor where the 24V Brake voltage is reduced and axis 2 is the first to overload.

Which model robot?

Does it always fault after long downtimes?

What kind of environment is the robot in?

Quote from NovaFlatline

Skooter, I may not be able to do that. Only because the superiors that be, don't allow me a pc. They say I am to dangerous. No risk, no reward is my motto.

They don't allow you to do a backup from the file menu?

Sometimes when instructions misbehave, I delete them and then recreate them. Same with the PRs. It's fixed similar problems a few times.

If changing it back to 1500mm/sec done as a background edit, try in teach.

Move all backups on the network and replace with one where the instruction is correct.

Check the RAM disk (RD) and FROM (FR) and make sure there isn't a copy of the program there too.

Is it both robots?

I suggest making a new 'All of Above' backup and then attaching the SUMMARY.DG file from the backup to this thread. This includes the specific I/O setup and software info that can help.

https://crc.frc.com/login.aspx

Fanuc customer resource center. If you don't have a login, you must register first.

I'm pretty sure $MASTER/CAL is not an actual variable. Do you mean $MASTER_ENB?

What version of software is this?

Perhaps the battery connector is not plugged in right.

If the battery is homemade then the voltage or polarity could be wrong.

Motoman part # is 479348-1, Yaskawa part # is ER6C3.

Look at the path speeds needed to make cycle time and consider one that is not too close to any limits of velocity and payload.

Are there cost differences in the dressouts? Training?

Consider the cost of offline programming.

For future costs, get intervals and pricing for PMs and compare over the 10 yrs.

Ask the manufactures about spare part kits and compare.

I remember seeing the Integrated PMC option with the offline FAPT Ladder package used on an R-J2 system.

The part numbers are shown in the R-2000iB Mechanical Unit Maintenance Manual. Don't see it available from the CRC manuals section with a ASI level login. But the manual is listed in the parts section under part # B-82235EN and B-82235EN-1. They are shown as special order.