ABB IRB4400 S4 CONTROLLER - DISC AND HELP REQUIRED

TylerAUS
TylerAUS ✭
in Robot Controller

Dear ABB Gurus,

Greetings from Australia!

A friend and I, both in the fiberglass business, recently picked up an ABB IRB 4400 M97A for an incredibly low price. We’ve wired it up and powered it on, but we’ve hit a roadblock. I have some experience with IRC5 models, but this is my first time working with an S4C controller.

I've attached as many details as possible, including images and system information, to this post.

Current Situation:

  • Controller Type: S4C
  • RobotWare Version (Suspected): 3.0
  • Status: The system is asking for the key disc and to press any key.
  • Issue: I don’t have the key disc.

Timeline of Events:

  1. First Boot-Up:

  2. Battery Swap Attempt:

    • Swapped in new batteries (though I now realize I didn’t leave them in for more than 10 minutes).
    • System then performed a cold start and now shows:
      "Insert key disc and press any key."

  3. Subsequent Attempts:

    • Swapped batteries again and left them in longer.
    • Still getting the same message:
      "Insert key disc and press any key."

What I’m Looking For:

  • Key Disc (or files needed to recreate one).
  • RobotWare 3.0 or compatible version to reinstall.
  • Any guidance on data recovery or alternative solutions.
  • If you're in Australia and have resources, let’s chat! My number is 0451 733 537.

Hardware I’ve Ordered:

  • USB-to-Floppy Drive (to attempt recovery).
  • New Batteries (to replace the dead ones).

Robot & Controller Details:

  • Robot Model: ABB IRB 4400 M97A
  • Robot Version: IRB4400/1.95-60
  • Serial Number: 44-05332
  • Manufacturing Date: 1998-01-29
  • Load Capacity: 60 kg
  • Power Requirement: 3-Phase 400V, 50-60Hz, 7.2 kVA
  • Controller Type: ABB S4C

Any help would be greatly appreciated.

Kind Regards,

Tyler White

Images:
https://photos.app.goo.gl/TmdFAvvaxkzQpmbw8

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