-- If the Thermal LED is also lit, consult the Power Wave three column
Troubleshooting Guide “Thermal LED is lit”.
-- The input voltage is too high or too low. Make certain the input voltage
is proper according to the rating plate located on the rear of the Power
Wave 455.
-- The Power Wave 455 is having trouble communicating with the wire
drive or control box. Turn the Power Wave 455 off. Disconnect the
control cable from the wire feeder receptacle on the power source.
Turn the Power Wave 455 on. If the status LED then blinks green, the
problem is external to the power source. If the LED is still blinking red
and green, consult Status LED Error Code Table.

"Status LED is blinking red and green:

3. Non-recoverable system fault. If the PS Status light

is flashing any combination of red and green, errors

are present in the Power Wave 455M (CE).

Read

the error code before the machine is turned off.

Error Code interpretation through the Status light is

detailed in the Service Manual. Individual code digits

are flashed in red with a long pause between digits. If

more than one code is present, the codes will be

separated by a green light.

To clear the error, turn power source off, and back

on to reset."

From Google

Our adjustment is a continuous thing. Not sure of practicality, that is just the way we do it. I can see the good dide of the force measurement angle as well.

As far as polishing/grinding wheel wear we shoot a laser across the leading edge of the wheel and computer in the PLC how much to adjust based on that feedback. Adjustment is done with a gearmotor and worm drive typically. Wheel is also mounted on a cushion to allow for part abnormalities with a sensor to determine that cushion has not stuck causing over adjustment.

Does your overhead crane rail have positioning sensors on it? Possibly feeding to a PLC?

Is so the programming to turn those position sensors to a screen presentation is quite simple, we have them in many places for different overhead or ground traveling machines.

https://schunk.com/us_en/gripping-systems/series/log/

Check out Shunk.

They have just about any gripper you want and the are well made and reliable.

Sounds to me like your power supply is failing.

That is why you lose power after set time, a winding opens or a solder joint separates from heat then as it cools it re forms itself. By the time you restart it things have cooled and it is all good. Reheats and re-fails. Lather, rinse, repeat.

Just my thoughts.

The EE connector is on the back of the robot arm itself. It feeds various solenoids etc on the robot itself.

With AB you have to have the version that the program was created under on your computer to open that program up. In other words it appears the program was created in version 0.3, the computer you are attempting to open it with must have version 0.3 RSLogix 5000 on it.

That sound you just heard was a bean counter crapping a large square cinder block.

Below is the instructions and cable pin out I have always used on our Rj2. Worked for me.

Kfloppy directions TO SEE USB PORT GO TO TOP TASK BAR>>>DEVICES>>>USB>>>SELECT PORT AND DOUBLE CLICK. Turn Off Screen Saver And Hard Drive Shut Down To save program: Open Kfloppy >>> Set comm portt>>> In KFloppy Folder on Desk Top: Create a File, Example: “837_5_18” this is the robot number and the month and year of back up. Longer names will not work. Under File Click Change Directory >>> change directory to the file you just created >>> Under File Click EMULATE, At the top of the Emulate pop up you should see the file name you have just created. If not abort and go back to Change Directory and check your typing etc. Disable your screen saver and Power downs on your laptop. >>> On TP: Press Menu >>> Select File >>> Utilities >>> Set Device >>> Enter >>> Floppy >>> Enter >>> Press Back up >>> Select All of the above >>> Enter >>> Yes .>>> If cable is connected the Save starts automatically. >>> Will read, “Accessing device. PREV to exit” >>> Then “Backing up xxxxxx” If all is well. If you receive a communications error check comm cable, if all is well try the following: On TP: Shut down controller panel >>> Perform a cold start by holding “PREV” and “NEXT” buttons on the TP while restoring power until the display reads options including “Cold Start” enter the number for “Cold Start” then enter. Wait for cold start to complete then press Menu >>> Setup >>> Port Int, >>> Choice >>> PS100/200 >>> Enter. Perform a second “Cold Start”. After cold start completes reattempt to perform back up again. To restore previously saved program. Make sure KFloppy is booted up >>> Turn on robot main power while holding “prev” & “Next” >>> press Next twice >>> press Install >>> press Enter >>> press Next >>> press Restore >>> press Enter. During Kfloppy upload teach pendant said “System not set up for serial floppy.” Performed “Cold Start” >>> Menu >>> Port Initialization >>> Changed port to PS-100 PS-200 option >>> FCTN >>> Cold Start >>> All Good KFloppy cable for R-J2 Controller ROBOT PC25 pin male connector 9 pin female connector 2 <--------------------------------------< 2 3 <--------------------------------------< 3 7 <--------------------------------------< 5 6 >--| |--< 1 | | 8 >--| |--< 4 | | 20 >--| |--< 6 4 >--| |--< 7 | | 5 >--| |--< 8

Just to clarify.

When you grease there are two plugs to remove.

Or a grease zert and a plug. If there are two plugs one will need to be replaced with a zert.

The plug will usually be opposite of the zert, and preferably pointing down, if not rotate robot so it does point down and then place a catch basin of some type under it.

Then begin pumping the grease into the zert SLOWLY. If you are using a pneumatic gun set at very low pressure. To high of pressure will destroy the seals in the joints.

As stated before pump until grease runs out clean and then remove a small amount to avoid over pressure caused by movement and heat up.

If you have not tried installing a backup of the system that would be my first move.

If your batteries died you may have to reload operating system.

"They did not have BG Logic until Rj3iA or iB. What you may be seeing is possibly a condition monitor or a connect IO."

This was the answer I received for a similar question in this forum a couple of years ago.

If I remember correctly it was not standard.

Another question, does the history reflect alarms from normal conditions or do they pop up randomly during operation as well?

Is this a newly commissioned robot or one that has been running and this just appeared?

Hope you followed the lubing rules or you cost yourself another seal and the tear down to replace. Good luck to you. As HawkMe said the pressure is the easiest thing to do wrong.