Once it boots up, does it stay running?
Fixes that I've seen for this problem:
- Reseated circuit boards and connection in computer unit.
- Reloaded/updated software.
- Replace CPU board.
- Replaced the SSD (HDD).
Once it boots up, does it stay running?
Fixes that I've seen for this problem:
- Reseated circuit boards and connection in computer unit.
- Reloaded/updated software.
- Replace CPU board.
- Replaced the SSD (HDD).
Putting a spare M94A controller together with a spare M96 IRB6400 arm for in-house project. Trying to load the 2.1 software on the M94A but it won't load - mostly gives a 'can't find IOC load' at the beginning of Boot Disk 1. Tried different disk sets and even an old ABB service generic, making sure the sets all had the same ID. Have the DSQC325, 326, 317 combo which should work according to the compatibility matrix. The controller & robot work fine with CommWare 2.0 but the Elmo/Siemens IRB config does not let the robot move linear very well.
I don't remember this being a problem but it has been a long time since I tried this. Spent too much time digging thru disks and loading them on a USB to give now (read stubborn). Any well 'seasoned' ABB folk know the answer?
For BaseWare 3.2 software, there should be a system pack of approximately 10 floppy disks. To be able to load the software, you must have the key disk specific to your robot. The key disk will load the encoded keystring that determines what gets loaded from the disk pack. From there, just follow the prompts.
Programs: At the Manual menu, select "TO DISK". It will read the disk, display the used blocks and then ask you for a block #. Entering an existing block will overwrite it or enter a new block # (between 0 & 999) to save to disk.
Parameters: At Manual menu, select "PARAM" and then select "TO DISK". The parameters will be saved to a hidden block (directory) and will overwrite any parameters already on the disk.
I would use a new disk if possible. Need DSDD, having unformatted is best but you can initialize (format) an IBM compatible if that is all you can find. Make multiple backup disks, they do go bad sometimes.
Backing up is a precaution before changing anything. It's not necessary to change the SMB nor is reloading a backup.
Not sure if I understand your question. Replacing the S3 SMB unit is simple as:
Have you tried restting the SiS? Does it have a module “sis-instr2”?
Try reseating the connections on the SMB unit and look for damaged cables/wiring. Most of the time, it's the SMB though and you'll need to replace it. If I remember right, the IRB1500 SMB unit had different mounting than the other more common robots. Post again if you have problems finding a replacement and I'll dig through some old notes.
The DSQC230 computer should be fine, it will not allow motion, rev counter updates, sync, etc. until the SMB error is fixed.
Good luck.
You'll need the adapters that dha suggested and then the compact flash to fit in the CF-to-PCMCIA adapter. There are many compact flash (CF) to choose from on eBay, for example:
http://www.ebay.com/itm/32MB-64MB-…=item1c54a37f72
Don't exceed 512MB or you may have issues. The 128, 256, 512MB sizes work good for me. You must format it in the controller before you can use it. After getting it to work, I suggest getting a few more. Good luck.
Check the calibration. It can cause this if it's off.
Look at the part number on the sticker located on the top of the big capacitor.
Your S-420iW should be A06B-6076-H001 or -H101.
The S-12 should be A06B-6076-H004 or -H104.
These are NOT compatible. The smaller power output of the -H104 amp will not be able to drive the large motors on the S-420iW.
Compare the current ratings on the stickers to see the difference.
FYI - The top boards do not swap either.
Since it happens while welding, this could be noise on the resolver signals:
Route weld cable away from robot cables.
Visually inspect manipulator cables and make sure the shielding is not damaged.
At the SMB unit in the base, make sure the exposed shielding of each feedback cable is tie wrapped to the metal bracket on the SMB unit.
Check and verify the continuity of the axis 6 cable shield from motor to SMB unit.
Check grounding - make sure everything is properly grounded.
Problem can be hard to find if the shield issue is intermittent.
If the both servo amps are the same, try swapping their positions. Not a likely solution but easy to try.
Try another SMB unit (move robot to cal position first).
bob865 is correct but I want to add:
The controller checks to see if the joystick is in its neutral (center) position when motor power comes on. This is a test of the joystick to make sure there is no unitentional motion from the joystick being broken or if something is holding it to one side.
The joystick is spring-loaded to be self-centering. Make sure the joystick is secure in the pendant, the boot is not damaged or kinked and nothing is touching the joystick everytime motor power is applied in Teach.
The robot will run in Auto because the controller ignores joystick signals while in Auto.
dha - just curious, but why wouldn't you use HOLD and then the Fence input to stop the robot? What am I missing?
I agree with Somar and DaveP. Moving the Mode Switch is very common, B-style controllers up on mezzanines is a good example.
Local is best to save on shipping cost. You can check with Fanuc or other robot manufactures to find local integrators. Many integrators either make them or purchase them locally to save on shipping costs. You could also try local robot reseller's. Many times robots will come with a base when they are purchased at auction/surplus.
ABB should have these. It's called a "Rod End Bearing".
Part # 3HAA2301-12
These should be greased on a regular basis, but many don't know how to grease the small flush fitting on each bearing.
It's been a while but I pretty sure you can still assign the two grippers with the Arc Welding firmware. They should be under System Outputs in the parameters. Try assigning them.
If they're predefined as System, then you should see an output toggle when pressing the pendant gripper open & close buttons in teach mode.
After reloading parameters, can you OK the errors and jog the robot? Do not commutate or calibrate the robot. Just move it back to the sync marks and reset the Rev. Counters. If you can't jog it, what is the specific error?
Don't discount a bad TPU. When the TPU first starts, it displays a title screen then waits to establish communication with the Robot CPU. If that doesn't happen after a short time, then it displays the Lost Communications ... message. If you've done a cold boot then the TPU should display the diagnostic routines that run as part of a cold boot. If the pendant is bad then you'll not see the diagnostics running. Try another pendant or verify the one you have if you can.
You can also try watching the disk drive to see if it is accessed after approx 3-5 minutes after turning the controller on. This would indicate that it has successfully completed the diagnostics and is looking for the boot disk to load software.
Was this unit running or is this a start up?
For your IRB6400, you need to move axis 2 forward and axis 3 down so the counter weight is up and out of the way. Axis 1 should be near 0 deg.
Pull the screws on the SMB unit and only remove the R2.X2 connector.
Pull the screws on the Brake Unit (has brake release buttons) so it can be accessed.
Remove axis 1 cover (toilet seat) to access and disconnect connections R2.MP1 at axis 1 motor, R2.MP2, R2.MP3, R2.MP4, R2.MP5-6 and R3.BU1-6 on the Brake Unit.
Remove the screws to the cable plate and the access plate on the opposite side.
Disconnect the ground wire and remove the nuts holding the cable in place. It's not easy if the access to the rear of the robot is blocked
Note how the cable track is situated before pulling the lower harness out so you can make sure the new one is folded the same way.
Pull the cable harness out.
Inspect and wipe down the nylon glide with a clean cloth and remove any debris/grease from the cavity.
Reverse the process to install.
Typically the red LED indicates a short in the 24VDC. To help isolate try:
Remove XT31 24V I/O fuse(s) to isolate 24V going to the I/O.
Pull XT1 - XT4 terminals from the Panel Unit to isolate the Run Chain.
Disconnect the teach pendant to isolate the cable and pendant.
Let us know if that doesn't isolate it.