Hero-2000 Robot Trouble Shooting


ET-19


Power Supply: 1Voice Problems: 2Keypad/Display Problems: 2RS-232 Problems: 2Status and Sense Functions Problems: 3Sonar Problems: 3Motor Problems: 4CPU Problems: 4Arm Problems: 5Remote Console Problems: 5

Power Supply:

Problem Possible Cause or Test
Robot is completely inoperative
  1. Check F102
  2. Check P11, P213, P15
Battery will not take charge
  1. Check setting of R148
  2. Check for +15V at charger
  3. Circuit Breaker CB1
  4. Check Fuse F101
  5. IC U107 or associated circuitry
  6. Transistor Q1 or Q2
No main +5 Volts
  1. SCR Q105
  2. Transistor Q110 or Q111
  3. IC U105 or associated circuitry
No sleep +5 Volts
  1. SCR Q107
  2. Transistor Q112 or Q113
  3. IC U107 or associated circuitry
No +12 or +25 Volts
  1. A. Transistor Q102, Q103 or Q107
  2. IC U102 or associated circuitry
  3. Diode D101 or D102
  4. Capacitor C104 or C105
No +12V, 25V source is okay
  1. IC U101 or associated circuitry
Setup function or battery function inoperative
  1. Check placement of JP101
  2. IC U104 or associated circuitry
Float charge function inoperative
  1. Check setting of R148
  2. IC U103 or associated circuitry
  3. See battery will not charge
Sleep function and status function inoperative
  1. Check P101, P103, P407, or P15

Voice Problems:

Problem Possible Cause or Test
No sound; voice indicator does not light
  1. No connection between I/O and status circuit boards.
No sound; voice indicator lights
  1. Check P402 or P403
  2. Check P701 or P703
  3. Check speaker connections or P702
  4. IC U703 or associated circuitry
  5. Problem on I/O circuit board

Keypad/Display Problems:

Problem Possible Cause or Test
Display and keypad are completely inoperative
  1. Check P403 or P701
Keypad is inoperative; display is okay
  1. IC U702
Display is inoperative; keyboard is okay
  1. IC U701
One 7 segment LED is inoperative
  1. Corresponding LED (D701 through D707)
  2. Corresponding driver transistor (Q703 through Q709)
One LED segment is inoperative
  1. Corresponding driver transistor (Q701, Q702, and Q710 through Q715)

RS-232 Problems:

Problem Possible Cause or Test
RS-232 port is inoperative
  1. Check for proper baud rate
  2. Check for proper handshake
  3. Check serial jumpers on the I/O board
  4. Check the cable for proper pignut
  5. Check for -12V; if not present see Status and Sense Functions Problems

Status and Sense Functions Problems:

Problem Possible Cause or Test
All functions are inoperative
  1. Check P406 or P603
No -12volt source
  1. Transistor Q601 or Q613
  2. IC U601 or associated circuitry
  3. Diode D613 or D622
  4. Capacitor C604 and C609
Sound sense inoperative
  1. M601
  2. IC U605 or associated circuitry
  3. IC U603 or associated circuitry
  4. A/D converter on I/O circuit board
Temperature circuit inoperative
  1. Check P604
  2. IC U604
  3. IC U602B or associated circuitry
  4. A/D converter on I/O circuit board
Light circuit inoperative
  1. Check wiring to LDR in sonar housing
  2. Sonar inoperative. See "Sonar Problems"
  3. IC U602A or associated circuitry
  4. A/D converter on I/O circuit board
All senses are inoperative
  1. One of the senses is overdriving the front end of the A/D converter
  2. A/D converter on the A/D circuit board

Sonar Problems:

Problem Possible Cause or Test
Motor does not turn
  1. Check motor winding to sonar encoder circuit board
  2. Check P901 or P401
Motor can not detect home position
  1. Check mechanical alignment of SW901
  2. SW901
No pulses heard from transducer
  1. Check wiring to transducer
  2. Check P401
Inaccurate sonar readings
  1. Check I/O circuit board adjustments

Motor Problems:

Problem Possible Cause or Test
None of the motors operate
  1. Check jumper sockets on motor controller circuit board.
  2. Problems with address ICs U517, U518, U524
  3. Problems with control ICs U516, U519, U522
  4. Problem with clock crystal Y501 or IC U523
  5. Problem with data IC U520 or U51
One motor does not operate
  1. Switch control channel to determine if problem is with motor controller.
Controller problem
  1. Check controller components, including processor, associated with bad channel
  2. Check MOSFETs, drivers, and inverters
Motor problem
  1. Check connection to plug P501, P502, P503
  2. Check connection to plug P801 on corresponding motor encoder circuit board.
  3. Check main interconnect P15
Erratic motor operation
  1. Check all connections under "Motor Problem"
  2. OS801 or OS802
  3. IC U801 or associated components

CPU Problems:

Problem Possible Cause or Test
Robot passes CPU test
  1. Check all I/O circuit board peripheral devices (particularly the sonar) outlined in this section.
  2. I/O circuit board problem
Robot fails CPU test
  1. CPU circuit board problem
  2. I/O circuit board problem
Robot will not turn on
  1. Press the RESET key
  2. With charger disconnected, turn robot off and back on.
  3. Check to make sure battery is charged
  4. Check CPU circuit board jumper sockets
  5. Check CPU circuit board DIP switch settings

Arm Problems:

Problem Possible Cause or Test
None of the motors operate
  1. Check jumper sockets on arm motor controller circuit board.
  2. Problems with address ICs U517, U518, U524
  3. Problems with control ICs U516, U519, U522
  4. Problem with clock crystal Y501 or IC U523
  5. Problem with data IC U520 or U51
Gripper does not move
  1. Check motor wiring
  2. Check gripper encoder wiring
  3. Check plug P701, P702, or P505
One motor does not operate
  1. Switch control channel to determine if problem is with motor controller.
Controller problem
  1. Check controller components, including processor, associated with bad channel
  2. Check MOSFETs, drivers, and inverters
Motor problem
  1. Check connection to plug P501, P502, P503
  2. Check connection to plug P801 on corresponding motor encoder circuit board.
  3. Check main interconnect P15
Erratic motor operation
  1. Check all connections under "Motor Problem"
  2. OS801 or OS802
  3. IC U801 or associated components
Gripper bounces when it hits the upper limit switch
  1. Perform wrist cam adjustment

Remote Console Problems:

Problem Possible Cause or Test
Unable to place robot transceiver board into the alignment mode
  1. Measure voltage at test point RT (Remote Test). If you measure 0 volts, IC U423 is defective. NOTE: You may swap with IC U430 to verify
Change in display contrast and/or operational distance decreases.
  1. Batteries are weak and require charging or replacing.
One key does not work reliably
  1. Dirt or contamination. Clean the keyboard circuit board with isopropyl alcohol.
Bad uP appears in the display after you turn remote power on.
  1. U202
Meaningless characters appear on the screen of the external terminal used in the link mode
  1. Terminal baud rate does not match that selected on the remote and/or the terminal is not set for the ANSI mode.
Display is blank; no beep is heard when you turn on the Remote
  1. U203
Display is blank or all pixels are turned on
  1. Solder bridge between harness wire connections on LCD module
Inoperative pixels in the display
  1. LCD module
Keys are inoperative once you enter the Remote mode A. Transceiver circuit board problem. Pin 8 of P101 should be low when no signal is received. With the align jumper installed, indicator LED101 should be off.