The robot needs to be within 1 motor revolution of the sync position to reset rev counters. The sync offset values can be entered at any position.
Since this is a welding robot, do I assume it's arc welding and an IRB2000? If it's spot welding and an IRB6000, then the commutation offsets on the robot motors are 1.5708 and already set.
Tried uploading Revision L of the Compact Controller Product Manual but it is too big even zipped @ 29.4MB. It has updated info on conveyor tracking. Uploaded newer version of prints
Also have Conveyor Tracking Application Manual rev K and older if needed.
Newer revision
ABBs virtual robot has all the right parts that match the system. Could be some mechanical difference such as a wrong wrist or incorrect extension as Reboot suggested?
Jog each joint a specific number of degrees in the Jog screen and see if it matches physically.
Check for play in axis 1.
Does it happen every time?
Does it feel smooth while jogging axis 1 thru the area where the alarm occurs?
Try releasing axis 1 brake only and physically move the robot thru the area where the alarm occurs. Does it feel different in that area?
Did this start happening after a change was made?
Are there any external forces such as hoses or cables that may be causing the issue?
Does changing speed effect the problem?
Which axis is giving the alarm? Is there play in that axis?
Are you pressing 'Active' to store the parameter change in the EEPROM before it reboots? Cycling power like an S4 & newer or a Fanuc does not store the change.
If you have swapped the amplifier and the motor, that leaves the cable in between
I have had cable test good with an ohmmeter but check bad with an insulation tester (megger).
A detailed examination of the cables and wires may find the issue. As Reboot said, the robot-to-controller cable is a great place to start.
I use a 0-60VDC @ 5A adjustable power supply with a pair of 36" minigrabber-to-banana leads.
I also use it for 24V brakes on other robots, many other voltages, and even charged my car battery in a pinch on the road and at work. You have many choices for under $80USD on Amazon and eBay.
Fanuc 90V brakes easily open at 60VDC and should stay open till under 40VDC. Neg to brake common and Pos to which ever brake. A pinout for connector RM1 will give pin numbers.
For axes 2 & 3, I suggest a strap to a hoist, fork truck, crane, etc. These axes are heavier than they look. Try axis 1 first to get used to your setup before attempting axes with stored energy.
Please be very mindful of pinch-points.
Only seen this as a result of a collision, but rarely to this degree. Since it's J3, something may have dropped on it. Double-check the paint. Gradual force will usually overcome the brake. I'd double check other axes too.
Regarding Soft-float, it is software based where it uses specified amount of energy to maintain its position and allows movement in the specified direction away from that point. It doesn't care about what the gear reduction is.
Register dumps are not good. Don't know if BACKUP02 is the FROM or CMOS.
Try deleting any programs and data not used. Change directory to FR and see if there are any copies located there that can be deleted.
There is risk and hate to mess with something working, but you could load in your backup and see if it overwrites the problem. Make sure you record your master counts and all frame data just in case.
I vaguely remember having this problem a very long time ago and it was something silly like the local/remote switch, sometimes bad Kfloppy cable, ...
Try toggling the large buffers in Kfloppy. Make sure logging is off.
Can you post a pic of the memory error?
Make sure the robot-to-controller ground wire is connected. Disconnect CRR88 and measure pin A1 to ground, should be open. If you have a megger, check it on the lowest voltage scale, 125V hopefully, always with CRR88 disconnected. Could be shorting to ground under voltage but measure good with DMM.
You can do an All of Above from the warm start file menu?
Your issue is trying to do a Controller backup from the CTRL Start 2 menu?
Not 100% on this but I seem to remember needing the controller backup option. Check Status menu > Config and see if option is there.
Doesn't that still leave parallel axis J1 brake as a possibility?
Do you have enough room to get a current clamp around each of the brake pins at the back of RM1:
11 - J1,
23 - J2,
33 - J3,
44 - J4,
45 - J5,
46 - J6
Rack 48 is CRMA-Honda connector for DI/DO found on Mate controllers.
Dynamic series connector CRMA16 on the Main Board for DI81-88 (IN21-28) & DO81-84 (OUT21-24)
Rack 48 looks to be mapped I/O for LR Mate peripheral connectors.
Peripheral device connector cable A2 plugs in to CRMA16 and has Honda MR50F
Details can be found in Mate Controller Maintenance manual and LR HandlingTool Operators manual
I just checked an R-30iA R-2000iB that did not have the EE connector. When compared to one that does have an EE, you can see the CRF8 connector on the servo amp is missing wires that would have gone to the EE. Tracing out the HBK on the robot that does have the EE should give the CRF8 pins needed. Adding the wires and enabling the variable that Erik Olsen provided might do the job.
I think the plan to use the OT is a great solution. Just wanted to give another possibility.
Check the Product Manual > Installation section > System Parameters > ...
Define board path:
Manual menu > Scan > Param > Change > In/Out > I/O Type
Digital Input path:
Manual menu > Scan > Param > Change > In/Out > I/O Use > I/O Map > Dig
The /02 on the system disk pack would indicate it is version 02.
The last version BaseWare 3.2 was 56.
I would try a newer version disk pack to see if it would help.
In the past, ABB tech support would supply a link to download the disk pack.
Note: You cannot load BW 3.1 after loading BW 3.2 as it will corrupt EEPROM on the DSQC373.
