So all your checks are confirmed electrically then as solid.
Can you obtain another teach pendant to borrow, or an E controller teach pendant (the E controller teach pendant will connect and work fine)?
The internal IO you are referring to is the 1KP relay outputs and the 1KB/1RB inputs I've been referring to.
These are enabled in Aux 0610 called Input/Output Signals in Robot Arm:
- User Sensor Inputs are for the inputs. (These are driven from 1KB/1RB board)
- Built in Valve Output are for the outputs (These are driven from 1KP Board relays).
- Link 9-10 and 11-12 provides the 24V and 0V power source to the arm IO harness, which can be removed and replaced by an external source on 10 and 12.
- You can disable these and see if it makes a difference.
- To my knowledge they never differentiated between Arm IO and 1HW IO until the Arm ID board was released (which is not fitted on FD50 Arms).
- They may have changed something in firmware to differentiate.....so try and disabling and see if it comes alive.
If this works I will really be apologising........as from what I recall when using the Arm IO (lets say on output 9), then output 9 would also be active on CN2 reflecting the Arm IO status......which was annoying as hell.