I had that problem but i dont remember exactly how we've solved it.
Try to play with rcu5000 parameteres, if it occus in the start of the welds, increase gas-preflow time.
And try cmt 2 -step trigger mode in ploblematic welds, now i think you work with 4-step special.
And don't forget about service and periodicial replacement of your wire channels.
It looks like my own thread
I ve solved all that problems by software reinstalling.
What was the symptoms: All modules were missing after warm start from the controller.
When you load them , you could handle robot in manual mode, but if you open production window or change to automatic mode there was tsksup.c 157 internal error.
There were a lot of problems with files transfer due to damaged floppy drive and we had to change it.
And also i've done booting for the first time and can say if you see the timeless start up counting dont wait a hour 
And the next question if i will try to reinstall the rw with that key disk id
Boot disk 1 (1)
Boot unit no 0 Make cmd 0 Wed Oct 24 08:39:15 2001
Program no 3HAC2700-1/41
Serial no 24-12070
Boot discette label text:System Key 3.2
Property of ABB Vasteras/Sweden.All rights reserved.
Reproduction,modification,use or disclosure to third
parties without express authority is strictly forbidden.
(C) Copyright ABB Robotics Products AB 1993.
And that robotware (has found on forum) with a sligtly different version of robotware and without
serial No on the boot disks.
Boot disk 1 (10)
Boot unit no 0 Make cmd 4 Fri Jan 20 12:45:13 2006
Program no 3HAC2700-2/56
Serial no
Boot discette label text:System Pack 3.2
Property of ABB Vasteras/Sweden.All rights reserved.
Reproduction,modification,use or disclosure to third
parties without express authority is strictly forbidden.
(C) Copyright ABB Robotics Products AB 1993.
Are there any chances that everything wiil be good?
Hello guys, I am new with abb robots, and extrimely need your help.
We have the 2400L m98 with s4c conroller, that hasnt worked about a half year.
After power on we have faced with a lot of diiferent file errors, did backup which showed that was empty, inspite
we saw all needed files in ramdisk.
Of course we try to restore worked backup and we have able to start program but it was blocked by "file not found erorr" at first variable from one of the system modules.
We do warm start and most of modules were erased from controller, and every time we do warm start they are erased again, inspite we still see them in ramdisk all time.
Even, when we dont do warmstart after restoring the main module cant see system modules variable's.
It seems like some problems with the memory storage, but maybe it's mere unknowledge of abb controllers.
In attachment two backups worked and empty and list of errors that were at start
Send me pm if you need key disk from that system.
And i will be very grateful if somebody share robinstall for me.
Thank you in advance=)
Hi Signum,
can you please share how do you solve that standalone jumper? What connections did you make? It seems that i have exactly the same system including this Safe Robot thing...
What connections you did on X11? Did you make anything on X40?
Thanks!
Hi,
I also faced with that problem,
Do you study what bridges are needed at x11,x12,x40 for stand alone working?
