Turning a broken 2 ton robot into a CNC-machine | ABB IRB6400

Here’s an overview of the project I’ve been working on for the past few months: resurrecting this 2 ton cast iron beast from the dead and turning it into a CNC milling machine, mainly for foam. The robot is an ABB IRB6400 / , manufactured in 1999. The documents that were still with the robot state that the original customer was the Eurostar train factory located in Austria, where it served as a welding robot. Upon the first startup attempt the controller wouldn’t perform a cold start and gave me : “Error 03:07003 Unexpected interrupt on MC“. After talking to some experts on the ABB robotics forum (thank you graemepaulin for your expertise) they pointed me in the right direction and told me to replace the main or robot computer. Replacing the Robot computer fixed te issue and the S4C controller was able to perform a cold start. I then installed Robotware OS 3.1 and after this i was able to get some movement out of the robot. Once the axis were callibrated again (b