A series of errors popped up on our controller seemingly out of the blue. A few weeks ago I set up a KRC4 attached to a KR6 R900 sixx with RSI that uses the RSI bus to actively control the position of the robot from an external controller via UDP(NI cRIO). We have had this set up working on another KRC4-KR6 set up with all the same specs. I had successfully set up the KRC4 and was working on getting my RSI code working on my external controller side. Then I went away for the weekend. When I came back the robot was showing some weird errors that I did not expect. The errors are shown in the attached picture, but I think the root of all of them is a lack of connection to the RDC.
At the start of this I had now idea what the RDC was or where is was located. Now I know that it is on the robot itself and that it stores a lot of information like robot position and safety configurations. We've tried all sorts of things from changing projects, reloading projects onto the controller from WorkVisual, and even restoring from 2 separate images.
There are two things to note:
1. When I remove the communication cable from the robot while the system is on (X21) another error shows up telling me that the ECAT bus to the RDC has an error. This suggests that there is some sort of connection between the robot and KRC4.
2. While trying to get rid of these errors, I was reloading projects and rebooting the controller over and over and one time it booted up and told me that something went wrong with the RDC and that I needed to choose whether to write the RDC with the archived memory. When I chose yes all the errors were gone. That is they were gone for about half a day until we tried to change projects again. After changing projects all the errors returned. I tried to go through the same process to clear the errors (changing back to the other project) but to no avail.
Any ideas what could be going on?
Any way to diagnose whether the RDC board itself is bad?
Basic Info:
KRC4 running KSS 8.3.25
Agilus KR6 R900 sixx