Posts by mk768780

We have made some progress. The debugging process we went through was as follows:

The COMPUTER ERROR I discovered thanks to Per @ Robot Spares was related to the The code means a fault with the Robot computer board pd bus and usually means replace the robot computer board.

PD-bus= communication bus for Programming unit / monitor.

This bus is on connector X5, the driver ICs for that are the 16pin DIP 26LS30 and 26LS32 as well as the DUART (68681) directly above those 2 ICs.

The enable into the 26LS30 was being driven but the data input was always high. We socketed these ICs as well as the lower DUART to allow us to swap the 2 DUARTs. After the swap, the TX data input to the 26LS30 is now being driven. Concluded a faulty DUART IC, drivers seem ok and we now have comms working.

We now move onto tracing through the run chain / limit / e-stop quagmire.

Regards

Merik

Hi

My name is Merik.

I have an IRB2000 S3 robot and can’t get it working.

I have done the following fault finding and repairs so far:

I have replaced the tantalum capacitor that was blown up on the main computer board and fixed the pcb.

I have only the computer, 6 axis cards and safety card installed at this stage.
I have replaced the nicad battery.

I replaced all the electrolytic caps in the power supply and voltages and ripple look fine.

I replaced the capacitors on the safety card.

The unit still gives me the following and nothing more when I connect a PC serial terminal on the sensor port at 1200 baud:

560 ERROR / ROBOT COMPUTER 0130 00

And the teach unit displays PROG UNIT COMMUNICATION FAULT

Any help for next step fault finding would be appreciated.

Regards

Merik

So the order has gone in. We have purchased all new electrolytic capacitors, film capacitors and a new tanlylum cap. A new nicad battery as well.

Should be about 5 days then we can work through the soldering and hopefully things start to work :-).

I’ll keep you all informed.

We are also going to try and replace all the output electrolytic capacitors in the power supply, We are seeing way to much ripple.

We have now discovered that one of the tantalum capacitors on the CPU board has failed and taken out some PCB track as well.

We have effected a repair without the cap and organising a replacement.

Still no luck.

A bit more work with a multi meter and oscilloscope :

We see the power supplies all looking ok with maybe a bit of noise on 24 volts. 500 nanosecond ring at 2 volts every 20 microseconds.

5 Volts is 400 millivolt noise peak to peak.

5 volt RVM has spikes of 4 volts above.

The battery has been removed until I get a replacement, not sure this will stop things working?

All cards are red led.

The teach pendant shows “prog unit communication fail”

The DSqC 210 has only one green led. Do all of them light up in normal operation?

Hi Everyone

Sorry about the duplicate but I posted most of this in the manual request section of the forum.
Skooter has been helping, thanks a lot.

I will summarise the work so far in getting my IRB 2000 working and then continue posting as I hopefully get to the bottom of the problem.

I first posted:

I have an IRB2000 with an old S3 controller and also looking for as much documentation as I can get. I am looking for wiring diagrams and service manuals if possible. I have searched about and most of the links on this forum seem to be quite old and expired.

At the moment every board on the controller has a red error light including the CPU. Not sure where to start?
I am trying to confirm what pins on X3 should be strapped to ensure that the external safety interlocks are disabled at the moment until I get it working.

Another thing I noticed is the NiCad battery pack seems to have leaked and I assume its not working.

Looking for details on what I should be looking for on the various test pins on the VME bus boards, voltage or oscilloscope waveforms?

Skooter helped out with manuals and guidance:

IRB2000s were built from 1987-93. I like to call the M87-M90A "Old S3" and the M91-M93A "New S3". Because of the major changes between old S3 and new S3, please supply the model year designation (M87-M93A) or the serial number.

Whenever resurrecting old equipment, always verify the power supply as some of the main components in them deteriorate with age.

Since it has a DSQC215 CPU, it's either an M90 or M90A controller with an external axis. The M90 power units are YB560101-Gx, the M90A are YB560101-Lx. There was an M90A/2 but I don't remember what changed.

Make sure the 3-position mode switch on the CPU is in the RUN position.
Check the voltages at the test points on the front of the DSQC211 power supply. I remember the 24V was always high which was normal.

I tried posting a Product Manual for the M90 IRB2000 but the forum gives me an error. It is a 6.8MB PDF.

Try searching 'M90' in only the ABB section & Manuals ... child board of the forum. There are other similar posts.

I will now start posting the steps I have been taking.

Once again thanks.

Thanks

Any chance you could send the manual to me via dropbox or email?

Thanks so much for your swift response.

I can't find numbers like that, here are some photos of the outside and inside.
Hope you can identify by that means.

Hello everyone.

I have an IRB2000 with an old S3 controller and also looking for as much documentation as I can get. I am looking for wiring diagrams and service manuals if possible. I have searched about and most of the links on this forum seem to be quite old and expired.

At the moment every board on the controller has a red error light including the CPU. Not sure where to start?
I am trying to confirm what pins on X3 should be strapped to ensure that the external safety interlocks are disabled at the moment until I get it working.

Another thing I noticed is the NiCad battery pack seems to have leaked and I assume its not working.

Looking for details on what I should be looking for on the various test pins on the VME bus boards, voltage or oscilloscope waveforms?

Any help would be appreciated.

Thanks

Merik