From experience, no good comes from operating right at a limit. Soon as you do this, parts will show up on an even thinner pallet. Best to make change in tooling or by moving part/robot work envelope closer to each other. This should also give a better cycle time and less wear-n-tear on the bot.
Posts by Skooter
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What RobotWare/BaseWare software?
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I was told by non-technical person it's been $2920 & $3020 for new recently. No other details.
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If the pendant is stuck booting, then it is likely not communicating with the Computer.
Switch on power while watching the hard drive LED, if it doesn't blink then it's not loading from the drive. If you have a DSQC639 Computer Unit, this is a common failure of the internal power regulation on the computer board.
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No for swapping. These two C-series amps are not the same.
A06B-6066-H233 is 2-axis, L=12A / M=12A
A06B-6066-H234 is 2-axis, L=12A / M=40A
These amps are also used in old Fanuc based CNC so you should be able to find repair/replacement.
Another option are the SVUC replacements: A06B-6090-H233 and A06B-6090-H234. They have the same specs as the 6066 series and developed as they're direct replacement.
If you can find them, manual part #s are B-65005E & B-65195EN.
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As Nation said, the 32GB is way too big. Normally for R-J3, a 32MB CF with PCMCIA adapter should work. When CF cards start to fail, they can give similar errors. I've limped along enough to get a backup with a failing card by reformatting multiple times with the robot controller. For your R-J3, I would purchase multiple additional 32MB or 64MB cards which are now longer made and very likely used. Larger cards take longer to format. As Doctor_C mentioned, always format the CF in the robot controller.
What size FROM/SRAM memory does this controller have? (Status > F1[Type] > Memory > F2 Detail)
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The IRB4400 was for many years across 4 generations of software. Please be very specific about which controller you have and software you need. The more information you give, the more likely you will get help in a timely manner. See post #2 above.
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Good troubleshooting & explanation. It can be an issue with most robots where the motors are in the wrist and there is no axis 4 hard stop. Gotta pull that cover and check if you're not sure.
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When jogging J5, the J6 motor also turns to compensate so the mounting flange does not move. My guess is J6 motor is correctly moving to compensate but the mounting flange is moving because J5 is not.
There may be many reasons why J5 is not moving. A good place to start is to double-check all connections from the servo amp connection for J5 to the base of the robot. Many 'Lab' robots are used for a test bed for troubleshooting and verifying production robot parts and as an emergency parts source.
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See note in post #4. The resolver is precisely set to a specific position on the motor to give it a commutation of 1.5708 rad. Any good servo motor repair shop familiar with ABB motors will have the equipment and knowledge to set the resolver to the correct position.
I don't have the IRB1200 in front of me to understand how the SMB power cable could have been plugged into the motor resolver connector. Pins 3 & 7 in the power cable are the 24VDC and pins 3 & 7 at the motor resolver connection should not have continuity. The resolver should have resistance between pins 1 & 6, 2 & 7, 3 & 8. Resistance should measure the same between 1 & 6 and between 2 & 7.
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Regarding rev counters, jog all axes to their zero position and any that don't match - update those counters.
Closely double-check the pins in the resolver connector for axis 2 motor. Perhaps a pin is pushed in or bent.
After axis 2 motor is changed or removed, you will need to do a Fine Calibration on axis 2.
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For me:
SMB = Serial Measurement Board is the PCB.
SMU = Serial Measurement Unit is the entire unit - metal mounting frame and PCB.
I'm a proponent of making sure the SMU frame is grounded and the cable shielding grounded. Fixes noise that causes other, sometimes intermittent issues.
Have you tried another SMU? Do you have another ABB motor to try just the resolver - resolver connections are standard across many ABB motors.
NOTE! Do not remove or loosen the resolver.
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Welcome to the Forum!
Reseat the connectors on the SMU and make sure the cable shields are tie wrapped back to the metal.
Is the error on 1 axis or many?
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Make sure there is no floppy in the disk drive when you power up.
The pendant is communicating as it displays the beginning screen showing the RDG/SBV EPROMs found on the Robot Computer board.
From there it will run through a series of system diagnostics tests where it displays each test as it progresses - please see troubleshooting tools section in the Product Manual.
Some tests take awhile so be patient. After it successfully completes diagnostics, it will ask for disk 1 of the software to be inserted into the disk drive.
Most common failure for S4 diagnostic tests is T0018: IOC Battery-test. This happens when one or both of the controller batteries is too low.
Since this has SBV/SDG EPROM set, download this IRB6400 M96 Product Manual found >here< and use the sections pertaining to the controller & software. It better reflects what you will see than the info found in the early edition IRB2400 M94A Product Manual.
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Which diagnostic screen/code is it stuck on? Codes start with a 'T'.
Did you download the manuals found >here< and >here<?
After removing the batteries, it will now need the operating system installed.
The operating system will have 5+ disks, not sure what you have on those floppies but hope there is a backup on one of them. The backup will not restore the operating system, but it can give clues about what else is needed and it will save lot's of work configuring the system after an operating system is loaded.
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The joystick needs to be in its null (center) position when self testing at power up. Double check the rubber seal around the joystick stem and make sure it is not deformed or push down too far.
Any 3HNE00313-1 teach pendant will work right off the shelf, these were used from S4C M97 thru S4C+ M2000A.
For the 00313-1 pendants, joystick failure is the most common failure excluding physical damage to pendant/cable/connector.
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It's hard to find floppy drives that allow the changes needed - D1>D0, DC>RY, SE>P2.
I suggest the replacement offered by Global Robot Parts (SWEROB) in Sweden.
Disk Drive Replacement (DDR) - A product to solve floppy disk problemsThe DDR replaces all old floppy disk units in ABB robot systems (S2, S3, S4, S4C and S4C+ with DSQC540 computer)www.globalrobotparts.comIt's mature & proven, they designed these years ago when floppies were being replaced by other media.
Bought a lot other quality ABB stuff from them, mostly before eBay became popular.
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ABB floppy format before IBM PC compatible - has different track/sector setup.
If 3.5", use an unformatted 720MB disk and format it in the controller - always format in the controller.
If it is already PC formatted, I would format it at least twice as bulk formatting usually penetrates the magnetic media to a greater depth.
I would recommend buying & using a cleaning floppy disk first - there's plenty still found on eBay.
If you don't have a key, you can jumper the switch with alligator jumper wire temporary.
Robot won't allow Automatic unless pendant is in the cradle.
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Posted S4 external axis information in the manuals, software & tools section. There's some recommended motors listed in the M94A configuration appendix table B.