Posts by s3 fanatic

Im pretty sure I found my issue. I decided to pull the manipulator harness out completely, and visually inspect the cable. I found a spot on axis 6 resolver cable was completely worn down to the wire because of the degrading cheese block (not sure what the proper name for this) that holds the cables together on the upper half of the lower arm. The cable was constantly rubbing against the mounting bracket as the robot was in motion. Apparentley the robot had jostled this cable in specific way that when checked the cables were fine. I have installed a new manipulator cable and it has been back in production for 48 hours with no issues. Wanted to thank you guys for all your helpful information and I will apply it for future troubleshooting.

Skooter,

It would have been between A5 and Pin 10 on the SMB connector .

Lemster, Skooter:

Update: I did replace the upper cables. So far no luck. Tried to check the configuration but got other errors in the process as seen below. One thing is for sure they all related to the same axis. As I was rechecking the lower cables for axis 6 I did come across that the resistance was slightly higher(2 ohms on one wire compared to .3 ohms on the others in relation to the resolver cable between the SMB and upper cable. Not sure if this normal because I dont have anything to compare it to. Looking into buying the lower cables, motor and the SMB. As of now I dont have any of these in stock. The question is which one is more likely to be the problem?

38651 Warning: Torque Current Ref. Error 0323 10:35.55

The torque-current reference is changing too quickly for joint irb_6.

->38652 Warning: Motor Angle Ref. Error 0323 11:47.57

The motor angle reference is changing too quickly for drive unit, joint irb_6.

->38031 Error: Resolver signal error 0323 11:48.5

Too low resolver voltage detected on joint irb_6.

2 piece base to upper arm the wrist

Thanks, This is great info. I have to look into COG. Never pay attention to that. I have always looked at load data and tool data. Is COG data based on the load data and tool data. What should be placed in this field?

Its 175. Excuse for me for asking, what is COG? Ive heard the term but cant remember what it stands for.

Tool Load 60lbs(132 kg)

Payload 9 - 15 lbs ( 4-7 kg)

50052- The speed of the joint is to high relative to the speed.

Having a problem with error code 50052 on Axis 6 along with ocassional collision fault. Tried looking for loose or broken grounds,reducing velocity and adjusting sup parameters before posting my problem. I have read other forums that seem to be related. Havent replaced axis 6 cabling or serial cable yet. Is there anything else could be missing ?

50052- The speed of the joint is to high relative to the speed.

I am assuming this is located in the s3 service manual. I have searched on this forum, I've seen all others but I have not come across the s3 service manual. I do have the irb6000 service,programming and product manual but do not have an s3 service manual. Do you have a copy of the s3 service manual?

Is there a way to check that on the s3's?

Robot model: irb6000
Controller: s3 M93

Having a problem with my axis 4 vibrating when idled. Also when idle it is drawing about 3.5-4.5A on 2 of the legs with out any motion. I have checked each leg to ground and found no shorts. I have checked the resistance of each leg and each reading is consistent from leg to leg. The cables for this axis have been replaced about 2 months ago. Also tried switching drive cards and found no change. Only thing I have not done is meggar test the motor. After about 3 hrs this motor has an average temp about 110 F before reaching a high current fault. I am leaning towards the motor being my problem but at the same time I'm thinking it is something else. I only say that because I have a spare robot here and pulled off the same axis motor and tested it on the robot that I am having problems with and has some very slight oscillating when idle. Any help or guidance is highly appreciated.

I do have DSQC223 cards . The cards themselves have no fault on them. There are other inputs on these cards seem to be working just fine but there are a selected few that just don't register when the inputs are turned on.I don't recall changing any parameters. But you got me thinking. It did lose it memory recently and I had to reload to the parameters and the programs.I never touched the parameters since dealing with these but I'ill have to check to see if the parameters changed on the backups or it didn't load the parameters correctly.

Thanks for pointing that out.
ill keep you posted

I'm having a problem with my input/output rack or cards. Recently one my robots have stop have stop responded to the inputs that are given in its instructions.I don't have any problems with the outputs. The following things that have I checked thus far are listed below.

1. Checked the supply voltage to the I/O cards. - Checked ok.- There is 24vdc volts being supplied to the I/O boards.
2. Checked the output voltage off the ribbon cable and the input voltage feeding the relay when the input is turned on. - Checked ok. There is 24Vdc going out from the I/O board to the I/O card when the input is turned on andv verified 120vac to turn on the relay to the input.

3. Swapped and changed I/O cards in the rack to see if the problem would follow. - No change.
4. Checked I/O cards to see if they are receiving the inputs. - YES, the led is on the I/O cards are lit when receiving the correct inputs.
5. Swapped out CPU card. - No change. Problem still exist.
6. Checked the instructions for the input in the program. - Didn't see anything or changes in the program. Made a simple program that would make the robot respond if and when the input was received.

Only thing I haven't done is swap out the back plane that connects the I/O's and the CPU. What are my chances the back plane that connects the boards in the rack going bad.

Is there anything else I should be looking at?

Help would be highly appreciated

Update: So far I have a narrowed down to couple of things
1. Found that the pins were recessed back in the connector on the motor side for the resolver for axis 4 when I started tracing. So I replaced the pins on the connector because the tabs that lock the pin into place had collapsed no longer holding them into place.

2. After I found the pin problem it came down to a servo error on axis 4 for the resolver when moving axis 2 or 3. Only found this due to only making a small program to do one movement at a time and for each axis to see if I would get an error. It seems to be any movement up,down, backwards or forwards it would error. So I came to conclusion the cable that runs in the chest is causing my error. So to make along story short I replaced the cable that runs from the axis 4 resolver to the SMB boards and so far i have no errors and works fine. I am confident that this has fix my issue but that not confident that there is some other problem lingering once I put the robot back into production. I'll keep you posted on what happens next.

Thank you Skooter and Roboweld for all your help

Thats pretty much what I got when I measured on the resolver in each leg. I dont have a scope to test those but will keep that in mind for future reference. But as far as that it seems ok.

Thanks Roboweld
I will try that. After looking at the schematic , there are three legs on the resolver and assuming that I should be getting 20 ohms on each leg of the resolver. Axis 1 seems to be a hit or miss sometimes but I need to check the resolver on that also. As far as trying to sync it in the calibration position it will never let me get that far. It will either do one or two things, its not very consistent at all. It will either boot up and find nothing wrong and able to move axis 4- 6 with no issues until I start moving axis 2 or 3. Or it will boot up and give the 2201 error right away preventing any movement until the problem is resolved.

Need help with IRB 6000 with m93 controller synch error. I keep getting an error code 509 Synch error 2201 along with 506 Servo error 2 (2004)(7001). I tried replacing the SMB board along with replacing the cables to the resolvers on axis 1-3 because the cables did not look healthy.. I also tried replacing the main measurement cable from the robot to the cabinet. Is there anything that I could be missing?. Please help.