I must assume you don't have a spare amplifier to try, since you never mention trying a different one.
Search the part # for the cable set, 3HAC9330-1 Upper Arm for example, and look at the pictures. The connection boxes on the back of the motor are part of the cable harness, you do not have to remove any pins from connectors.
You should make sure you find out if it's in the robot and not the robot-to-controller cable or the MP1 connector at the base of the robot.
Replacing the cable set without knowing if it's the problem seems expensive to me. At least try to find out if it's the upper or lower set.
Posts by Skooter
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To properly test, you must swap both the MP and FB connectors as a set.
MP4 <> MP5 and FB4 <> FB5.
When the motor is commanded to turn, the controller must see that it is moving (resolver) as it is commanded.
It may not change the outcome but I would do it just to make sure.Before attempting to change the internal cable, I would verifiy it was bad.
Have you ruled out the servo amp & robot-to-controller cable & connections? -
Please use the same advice as was given for your IRB2400.
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The biggest complaint I here from Fanuc trained folks starting out on an ABB is mastering the joystick. The trick is to remember is the joystick is an analog device, it has a slight delay between motion & action and there is a small off area in the center position. Move the joystick slowly until you hear the brakes release, that is where the joystick becomes active. From there, the speed of motion depends on the amount of deflection of the joystick. Use the jog screen whenever you jog the robot until you get used to joystick direction for each coordinate system. Once you get used to it, it's easier than constantly changing speed percentage when jogging.
Another difference is that data and I/O is named instead of numbered and then labeled. This makes it easier to understand. The data choices are much more extensive and powerful.
The line editing on a Fanuc is faster and being able to view 3 screens at once will be missed when debugging/monitoring.
Unlike Fanuc's policy, ABB manuals are somewhat easy to come by and ABB allows you to download & use a slightly diminished but still powerful RobotStudio if you don't choose to register it.
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Just want to add:
Do not remove or try to adjust the resolver. When the motor is built, the resolver is installed to give an expected commutation value of 1.5708. A motor with a resolver that has been moved from its original position can give the same faults.Per Iowan, did you try a different servo amp yet? Axis 5 is in the servo amp in the A2 (second from the right) position.
Also better to just swap the axis 5 motor (MP5) and resolver (FB5) connectors with either axis 4 or axis 6. Only replace the motor if the problem stays with the motor. Motor and resolver connectors are the same on all 3 upper arm motors. -
It has been a long time but I found some notes on the resolver connector:
Round, 8-pin Trim-Trio # UTG012-8P
Pins A - B = Cos @ 74 ohms
Pins C - D = Sin @ 74 ohms
Pins E - F = Ref @ 25 ohms
Pin G = Shield
Pin H = no connectionVin is 10VPP, Vout is 5VPP, frequency is 3 KHz
I prefer to use a scope with possible resolver issues because a shorted winding may not give a significant resistance change but will give a significant drop in output voltage.
Intermittent or low resolver output can cause the rev counter to be lost and many times the S3 does not give a reason why. -
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Iowan's answer and solution should fix the problem. Possible causes the Fine Calibration could be off: If someone has reloaded software but did not reload the MOC parameters that contains the Fine Calibration data. Look at the motor calibration parameters for each motor (IRB) and see if the cal offset numbers are all zeros. Another scenario is someone did a fine calibration at one time when the robot was out of position and then the robot was moved to marks and the rev. counters updated. Also have seen where fine calibration is off where a backup from another robot was used and now the offsets of a different robot are loaded. Any axis where the motor has never been removed should be able to use the fine calibration numbers on the back of the lower arm. Be aware the numbers are in radians so a revolution is represented by a number between 0 & 6.28319 (2*pi).
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Try to find the spot where the collision error stays. Usually suspect a bad cable, could be one of the parallel R, S, or T motor leads are open and causing current issue phase-to-phase. Check motor lead connectors from the amp to the inside of the motor and verify wires and connectors - also look for burnt or pushed-in contacts. A break in the resolver cable shield will sometime give collision due to resolver signal interference. An intermittent in the axis 3 brake wires can cause the brake to drop out.
Mechanically - was the TMO in axis 3 discolored in any way? Check the parallel bar bearings and the shoulder pivot bolts/bearing. Seen issues with the bearing in places where the robot gets washed down. Put your ear on axis 3 motor and listen carefully to axis 3 brake when it engages and disengages. Now listen to axis 2, does it sound exactly the same? -
There is so many thing little things that can keep the Main CPU from coming up and so many more that can keep the rest of it from running. Due to age, you would need to have access to an electronic repair facility just to replaced all the old out-of-tolerance capacitors. I would pass too even though I've fixed well over a hundred of these & rebuilt dozens more, they're just a lot of work to setup, maintain & program compared to a newer style. Can't let nostalgia override common sense. Good luck in your search.
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Still looking.
The manual is: ProcessWare User's Guide SpotWare Servo & SpotWare Servo Plus 3HAC12983-1.
Thanks! -
Do you plan on using the controller?
Hopefully, this was a running robot.
Already uploaded all my S2 manuals in PDF, like RoboWeld, any IRB90 manuals would be a hardcopy in a box somewhere - maybe. -
Same. I like to use duct tape to cover screw heads when letting grease drip down a wrist into a bucket, under a leaky fitting or anywhere else grease might get that is a chore to clean. Makes cleanup easier. A package of small, cheap bungee cords along with a strong magnetic hook helps manage vac & grease hoses. Stronger, longer bungee cords for hanging the vac near the grease outlet or holding the cabinet door open.
Always turn the regulator on the pump all the way down each time so it doesn't start fast by accident.
I have a small screw extractor (easy-out) for the occasional broken zerk, small set of metric deepwell sockets to remove zerks & a machinist scribe for digging out spatter from ports with socket head screws. New zerk covers to keep them clean till next time.
1/4" wide teflon tape or teflon pipe sealant depending on the need.
Knee pads for us old folk with banged up knees - for those robots mounted to floor or flat plates. -
Are you restarting after making changes to enable them and then saving your parameters?
An old S3 trick is to set the parameters to default and then restart. Then reload your saved parameters. -
If someone changed/updated the rev counter, it should be listed in the log.
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This sounds like an S4C+. Try reseating the computer unit boards and double check that all the connectors are properly seated and in the correct place.
Changing the 3V battery won't keep it from booting. If the boot image file is corrupt, follow Iowan's advice to search for posts that will tell you how to delete the corrupt image and allow the unit to finish booting. There is a guide in the manuals section for initializing using Hyperterninal. -
Only seen 2 IRB6400s that were arc welding. One was at GM Arlington and it was arc welding because all the other robots in the plant were IRB6400 and GM insisted on same for spare parts & troubleshooting. The other was simply for reach. Is this for reach or did you find it this way?
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The numbers after the / are revision numbers and most of the time have no effect though there are exceptions. The motors axis 1 & 3 motors are interchangeable. Added product manual in manuals section so you can read the motor replacement procedure and learn more about your robot. Axis 2 motor brake is holding axis 2 arm in position so when you remove the motor nothing is holding the arm so when you remove the motor...
PLEASE BE SAFE AND SECURE AXIS 2 ARM AGAINST ITS HARDSTOP BEFORE REMOVING AXIS 2 MOTOR!!!
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When the servo power is applied to the motors, 24VDC is supplied to the brakes to disengage them and allow motion. The motors do not overcome the brakes - imagine driving a car with the brakes fully applied.
To send you on your way to learning about the brakes, I searched "Explanation of servo motor brakes" and got this vidoe: "
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