This was for building replacement cables many years ago so the colors may be different.
Posts by Skooter
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Is it only the one position instruction that is shifted 20-30mm?
If so, please post the entire instruction.
Step thru the program in Auto to get to the position to ensure you are selecting the right position instruction to modify. Could be running a different position instruction in Auto than in Manual.
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Not sure why you want to reload software if that's the reason for a boot disk.
Software is loaded using a key string and RobInstall to create a system that can be loaded.
It sounds like you need to fix the I/O parameters.
Make a backup and post a copy the 'EIO.cfg' and 'backinfo.txt' files found in the backup.
That should provide enough information for someone to help.
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You're grease probably looks like a gold flake bass boat. I would open up a drain port and take a small sample with a shop vac. Your nose may tell you more than your eyes
Sometimes a long cable tie can get deep enough and the small ridges hang on to the grease. Hold a rag over the fitting/plug when you loosen it as there may be pressure in the cavity that can cause grease to rush out when first opened.
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According to Lincoln, code # 10943 does not match a PowerWave 455M. Could be code 10942 or 11943? Those are found in PowerWave Operators Manual IM762 found >here<
My guess is this model 455M may not be setup to drive the 10R feeder.
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If you're unsure about what options the robot has - do a backup and then post the backinfo.txt file found in the BACKINFO folder. The options and software version are listed in this file.
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If you can't move axis J5, put a piece of electrical tape across the closest part of stationary & moving part of the joint. Very carefully slit the tape with a new razor or box cutter blade. Record the joint position for the axis J5 for later. Replace motor, reset BZAL, reboot, move to establish pulses, move back to where the tape lines up. Single axis master the joint to the recorded position for the tape. If positions are slightly off, move to a position where it is easy to see how far the position is off. Look at the stored position values for that position in joint representation and record the value of the J5. Enter that value in the single-axis mastering value for J5. Move J5 to where should be and single axis master & calibrate.
I usually can avoid having to do touchups 90% percent of the time for a single joint motor replacement.
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The loss of the rev. counter is a symptom. Verify the cause is still the 20477 error.
Are there any additional axes besides the 6 on the robot where a second SMB is being used?
Are the ground (earth) connections in the robot making good connection? These are the green/yellow wires at the back of the robot.
Inspect the robot internal cable for damage coming from R1.SMB at the base up to the SMB unit.
Make sure the connections related to the SMB in the controller are well seated and the Axis Controller and SafeMove units are mounted and not hanging loose.
Make sure the robot-to-controller SMB and other cables do not parallel a high current cable, welding cable as an example. Run in separate ducts. If crossing a high current line, try to do it at 90 deg.
Make sure any nearby high current sources are properly ran and shielded.
You already tried 2 of the most likely causes. Unless other errors give you another direction, consider trying another SafeMove unit if the connections and cable routing are good.
A 20477 is a communication loss between the SafeMove unit and the SMB. Because it works most of the time, noise or loss of signal on the communication or 24V/0V between these is a possible cause. Any resolver issues would give errors specific to the resolvers and rev. counters for those affected axes.
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My old school approach would be to check the J1 motor temperature after a typical shift. My personal, undocumented temp where I start getting nervous is around 120F (50C). The cooler, the better.
Always look to minimize stress by optimizing motion, use joint and continuous positions whenever possible. Make sure the robot is not running full speed to a position only to wait many seconds.
If still running hot, contact Fanuc and/or your integrator and discuss adding a fan kit option to J1 axis.
Make sure the robot gets its grease exchange PM as scheduled, sooner than recommended if it runs hot.
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Remove the 7th servo amp and check the orange connector sockets and the matching rack connector pins. Make sure they are making good connection.
Measure motor resistance from inside the controller to verify wiring and motor resistance.
If the 7th servo amp is the same as one of the others, try swapping them and see if the problem moves.
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Glad you made it this far. What is the exact error and subcode?
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33156 - No communication with SMB as explained in post # 55. Fix this first and then see if the other errors are still there.
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My guess is the board configuration for address 1 and 3 is not right. Look at DSQC223 at board address 2 and make 3 the same except the name and address. The DSQC315 Combi board has the same 16-in & 16-out digital configuration as the DSQC223 plus the 2 analog outputs.
I would delete any user I/O that references the no longer installed DSQC260 Interbus board labelled "INTERB".
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Look at the robot internal cables under the base top cover and make sure the Green/Yellow ground wires attach the robot frame.
Look at the cables connecting to the serial measurement unit, the shielding of those cables should also be connecting to ground. If there isn't a spot for the shielding to ground, the shield may be getting its ground thru pin 1 of the DB connectors. I can't be sure as it's been a long time since I looked at an IRB7600 cable set.
I uploaded the robot schematics to the manuals section in case you need it.
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This is rev 6 of 3HAC025744-001.
Hope it helps.
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Although it been a few years, it also works on R-H. For R-H, toggle off the Large Transmit Buffers in the Emulator settings.
Toggle off the Log messages too.
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Download the User Guide and Rapid Reference manuals for BW2.1 found >here<.
I/O parameters are in the User Manual starting at page 12-9.
Regarding the I/O boards, I suggest making parameter changes thru the teach pendant.
In the picture above, the I/O boards are:
Address 1 = DSQC315
Address 2 = DSQC223
Address 3 = DSQC223
The I/O board addresses go from right to left, addresses 4-6 are empty.
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I've heard a bad drive unit cause sound like this. Does it do it with the robot-to-controller motor power cable disconnected?
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33156 is a missing communication with the serial measurement board. Make sure the robot-to-controller serial cable is connected.
The product manual will help, it contains the error codes. The M96 Product Manual can be found >here<.
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Yes. Knowing the serial cable configuration is correct allows you to concentrate on protocols and other issues when trying to get Kfloppy to work on WIN10 machines.