Posts by rib

A few days ago I have replaced the contactors, this did not solve the problem in the servo however was necesary because of the smoke,

Today I made a temporary cable from the encoder to the SMB. This is a sub-d 15 (encoder) -> IDC (SMB), which currently does not go through the bearing but is going from the outside to the SMB. This did solve the problem.

This week I will replace the connector from the original cable as the above is only temporary. Hopefully this will solve the problem because replacing the complete cable will be dificult.

The burned contactors is K1 or k2 indeed. But I will replace all 4 contactors. I will also check the shielding of the encoder cable.

Do you know how the cable is going through from axis 1 to the SMB. Is there a drag contact or something else? I see a cable carrier for the motor cables but for the encoder cables it looks like it’s going just through the bearing. But I cannot see everything.

And then there was grey smoke.

Today I replaced the encoder and now the noise is far less then it the beginning, although it is still there. Then I placed the robot in the position with the biggest amount of noise and I noticed that by pulling on the encoder cable the amount of noise was changing. From that point of time I got the feeling that the problem is maybe related to the encoder cable.

But in the mean time I did something else and then there was a strange smell and grey smoke in the S4 cabinet. The smell came from the relays which switch the power to the motor board. After measuring these the resistance was also high for a relays. Then I hoped that this was maybe the problem and found a temporary solution with a relays which can only switch the 3 phases for the motor supply so the other signals are still switched with the old relays. Unfortunately the same amount of noise is still present with this temporary solution. So for this I also have to find a more permanent solution.

So currently I am searching in the direction of the encoder cable. I am thinking of creating a temporary cable directly to the board. If this solves the problem: how is the cable going through the robot from the base to axis 2? It looks like the motor cables are going through a cable sleeve but these encoder cables are going through the middle joint directly.

Thanks for your reply.

I also bought now an additional encoder which I will get tomorrow. I will also try your points tomorrow if replacing the encoder does not solve the problem.

I have now replaced the motor to an used one from ebay, but unfortunately still the same noise. The pins of the XP1 connector looks nice also the inside. Also the connector is not getting warm, which I would expect with an loose contact.

I did both tests:

1) Pressed brake 1 axis and turned manually: i could turn the motor nice and smoothly.

2) While in jog window watched the amount of degree of each axis: nice and steady.
3) Previously I already interchanged the motor boards.

4) Also checked the resistance of the motor by uncoupling the big harting multiconnector from the control cabinet. Between all phases was almost the same resistance.

P.s. the check with the megger I did not do yet because the motor connector is difficult to reach.

So from my perspective:

It's not the brake (test 1), not the encoder (test 2), not the electronics (test 3, or it should be the backplane). So remains for me: cabling (most of it tested with test 4, but not all) or the servo (altough the resistance looks okay in test 4).

Some other ideas?

I already tried something similar to check the brake, but your method is more efficient. I will perform your tests this evening.

I also think to try to megger (isolation test) the coils of the motor. I am thinking if maybe the insulation of on of the coils is not okay anymore and therefore are leaking to the ground.

Small update:

Today I did the procedure to commutate the motor of first axis, see attached picture. I placed the motor in this posistion and then selected commute axis 1 in the service menu. Unfortunately this did not solve the strange noise.

Edit: also now swapped the servo amplifier boards inside the s4 controller but still the same noise on the same axis.

I can move the robot now

Only thing is that the motor of the first axis is making a strange noise it looks I sound a little bit as electricity flow or how you want to describe it. When not moving this is constant and when moving its pulsates with the speed of the movement.

Can it be that for this axis maybe the commutator values are wrong? And therefore the motor is not

Powered correctly?

I did now manage to get the right Baseware version for an IRB1400 during setup you can then choose for the IRB2400. This is now completely installed, and the system now at least start up again. But now the following problem arises:

- Battery of the robot itself is also empty.

Therefore, commutation also has to be done again probably. The only disk which I had was a boot disk so also no MOC.cfg file but I did found the encoder values, but only two times. Any tips?

I think it is "Boot discette label text:Basic 2.0". I did found BaseWare 3.0 on the forum: boot disks for S4 will it be possible to use this one and therefore to upgrade?

Br Rene

Edit: just checked but this is not possible. Probably I have the BaseWare basic 2.0 version. Hopefully somebody still have these disks

Hi,

I have just replaced the battery now the warning is gone, but the error is still there. Also tried to connect with the com port but no output. Therefore removed both batteries and now the system is at least performing the test (it didnt do that) and is then performing a cold boot. Now it is asking for the disks (as expected).

I inserted disk 1 which was okay and then asked for disk 2 which I did not have. Attached the disc.id file.

Does somebody has the boot disks?

Hi,

Thanks for your reply.

Attached the photo of the teachpendant with the warning (batterij) and error (diag). First I get the warning then the error. I managed yesterday to have boot disk 1 working again, the other ones I do not have. ABB_MC file was corrupt and could be repaired by windows. The disc.id file still looks okay.

Update: also disconnected to robot cables, but still the same error.

Thanks for the reply, I also do not think that by replacing the battery it will be solved, but I just have to be sure because when going for a cold boot definitely everything will be lost. Currently I am still waiting on the new batteries, so unfortunately no update. I did check the boot disks but unfortunately these are corrupt. What will be the best way to get these disks again?

ABB S4, IRB 2400 M94

Hi,

I have a ABB S4 + IRB2400M94A which will not start-up anymore after some years of no use. It gets an error: "Diag: Illegal Instruction, SR: 2014 PC: 0004C6A6". This happens during booting. What happens:

- Power on

- Boot screen will be shown: "Welcome to the S4 robot-controller"

- Warning. 03:01501 Battery 1 low voltage

- Warm start in progress.

- Then after a few seconds only It gets an error in only text: "Diag: Illegal Instruction, SR: 2014 PC: 0004C6A6".

I already tried searching on the internet but I cannot find anything regarding this error also not in the manual. Off course I also get an warning for the battery so I already ordered new batteries which I will getting a few days, but normally I would say a warning should not prevent that the robot will not start-up. Also a warm boot is performed so the memory is not empty. At least that is what I think.

The red LEDs on all expansion cards are red, according the manual this happens when the controller is not initialized, I think because it did not start-up currently.

Did somebody has got a similar problem? Or maybe an idea to solve it?

Currently my approach would be: I replace the batteries, to be sure. If this does not solve it I would clear the memory by removing the batteries and try to do a cold boot. The problem there is only I do have some disks for this but if these are the rights ones and still working..., I am doubting at least. Therefore I would like to use this as a last solution.