Posts by Sean_MMSNI

Got my hands on a refurbished wrist, swapped it out yesterday and robot is now back up and running. I checked the oil in the old wrist and there was only about 35ml in it and it was very dirty with a lot of metal floating about in it. I am guessing this was the cause.

Thanks for this. The robot is down at another site, I will check this out when I am next down at it.

I am also trying to source a used wrist so I can swap it out and try it.

Wrist has not been greased since install, I was told it was a non serviceable part. How/where do I add grease?

I should have added its a welding robot so is a fixed welding torch, Its been running roughly a year with no problems so the load data shouldn't be causing any issues.

I tried jogging in a couple of different orientations, I never tried fully 90 degrees and 180.

I did try manually releasing A5 brake and I was able to move A5 limit to Limit, however I did feel a slight roughness in some places. After doing this I would be able to jog A5 up past where it was sticking and run my welding program for another cycle then it would stop and throw the error again and jam up not allowing me to jog up again.

I have a torch cleaning station and every time it starts the torch clean routine, you can visually see the torch vibrate and judder as it try's to move down to the set position and it throws up these errors again. This happens every single time without fail.

If I swap motors for A5 and A6, I take it I would have to do a fine recalibrate?

We have an IRB2400L s4c+ robot that we purchased refurbished just over a year ago. It apparently had the wrist refurbed/rebuilt before we received it, however during commissioning/initial programming I was getting a lot of errors to do with axis 5 and 6 jamming up and causing over torque errors to pop up. long story short, the supplier sent us a replacement wrist that had also apparently been refurbed/rebuilt. I got the wrists swapped out and this seemed to fix our problems until a few days ago when these errors started popping up on axis 5 again.

When jogging axis 5 manually the wrist moves down to limit with no problem, however when moving it up the wrist stops suddenly roughly half way with over torque errors. It looks like the wrist has gone faulty again. Can the wrist be repaired or does it need replaced? any advice would be greatly appreciated. I have attached images of some of the errors I was getting

I got a quote from ABB for a brand new wrist, however the cost of the wrist is nearly the same as what the robot cost itself, so its not really cost effective.

Yes the old battery measured 10.8v also, I will double check polarity when I am back down at the robot.

I do have other robots I could swap the battery with to test, I will also try this.

If the error still occurs after checking these, would that point to a faulty SMB in the robot?

I measured the voltage at the battery itself when it was unplugged using a multimeter probing inside of the connector.

Robot battery is 3HAC16831-1

Controller batteries are 3HAB2038-1

I cant remember the exact valves however they were very close to the specified 3.6v on the controller batteries and 10.8v for robot battery.

Not sure if they are wired to the correct polarity as they came with connectors already on them, where could I find out what the correct polarity is?

I have a 6400 here with s4c controller and every time the power goes out I get the attached message saying "Battery backup on serial measurement board 1 on measurement system 1 lost since last power down or restart". I then have to go through and update rev counters.

I have checked both batteries (robot & controller) and they were fine however I replaced them anyway just to be sure and it still brings up message every time. Any Idea what would be causing this?

Also not sure if it is related, nearly every time it powers up it blows the breaker in the shed at first however if I flick the breaker on again it stays on and runs fine until there is another power out. I put this down to the wrong type of breaker being installed.

We normally wouldn't have very many power outs, however we have been getting a lot of bad storms lately and power outs are becoming more frequent.

We have purchased a new welding robot setup, it consists of an irb 2400L with s4c+ controller. It has a torch cleaning station and a bullseye with it.

I have a good deal of experience working with these robots, however I have never used a bullseye before and am struggling to set it up. The company we bought it from said the bullseye was already setup however I cant see any menus or routines to do with it within the robot system.

I have tried to follow through the manual to set it up. The manual I have been using is for BullsEye 7.0. I have run through the software installation process and got to software setup and this is where I get my first problem. Below is the extract from the manual, It tells me to select view, Modules and then highlight BULLSEYE which I done however there is no SetupBullsEye routine appearing for me. so this is where I get stuck.

Software Setup:

Prepare the robot, the torch and BullsEye® for use. With the Program Window visible on the

Teach Pendant, select the VIEW Menu Key, select “Modules”, highlight BULLSEYE and press

ENTER. Now highlight the routine “SetupBullsEye” and press ENTER. Press the TEST

Function Key. With the robot ready to operate and the enabling devise activated, you may

begin the program by pressing the START Function Key.

I have tried contacting the company we bought it from however they said they don't know what is going on and suggested I restored the original backup they sent with the robot and try again. I done this with no difference.

Anyone any ideas to what is going on, am I not doing something correctly or have I missed something?

Again I have never used bullseye before so I am only going off what the manual is telling me.

Thanks, this sorted it.

I have an IRB 6400R 2.8-200Kg S4c robot setup here, It has been stored up for a long time and the batteries in the controller have died meaning I need to reinstall the software.

I have got new batteries and fired up the robot and it has asked me to insert the disks as required, I follow through installing all disks then it gives me 3 options I select Query, select the language and then it asks for what type of DC link I have, I select DC4. It then asks me what type of robot, However it only displays 2.5 options and mine is 2.8

Have i missed something or how do I get the correct type?

Power Supply is DSQC365. Model year is 2002 M99

I measured this in the top compartment XT31, the 2 amp 24v point used for I/O

the meter is a cheap one the brand is DRAPER Expert

I have tried jostling all exterior cables to try induce a restart to no avail. I will try some of the interior parts to check them.

I have measured the ac voltage on the 24vdc output and I am getting around 1v as soon as i connect the meter, however this steadily but slowly drops down below 0.15v.

It happens both when the robot is moving and when sitting stationary with motors off.

yeah they are and its doing it when the welder is not active

The power outlet for this robot was only installed last week and there is another smaller IRB2400L beside it on a different Isolator that is not doing this.

The factory also has multiple manual welding machines running constant.

The robot appears to be warm restarting, do you think this could still be power related?

I have a an irb6400 here that's to be used as part of a welding setup. I had this exact robot setup down at our factory and it worked fine with no problems. I have now moved the robot down to our customers site and am in the process of programming it. However it is randomly restarting Its done it 6 times today alone.

Anyone any idea what would be causing this?

Thanks for your help, I went through and tested the wiring and it was ok and I was getting 24v down at the connector, so I switched the fans out with anther robot I had and they work fine now so must be the fans at fault.

Not sure why they work when I bench test them, must be a current draw issue

Thanks for your reply, yes it is s4c. I opened the controller while it was running and could see the fans are not running, I have followed your manual and removed the fans and tested them with 24v. they work fine so I am guessing what ever starts the fans or else the wiring is at fault.

Do you know is there a wiring diagram for the fan system or do you know what triggers the fans to turn on?

I have been running my irb6400 robot in automatic mode, when I came back to it I found an error had been thrown up. The error read as follows

Error 39209

High temperature alarm in

Drive Unit, joint: irb_4.

NOTE: ALLOW SYSTEM TO COOL DOWN:

does anyone know what would cause this to happen. the robot was only running for around 20 mins when it happened.

Found it, was just as simple as plugging it in and adding it through the teach pendant.