Intermittent CODE ERROR, followed by uncommanded relay switching

[tcj103]

We've encountered an intermittent problem with this years robot controller. We have the 2007 streamlined camera code on the robot, as provided on Kevin Watsons web site. Once in a while, we'll power up the robot, which will set a "code error" on the controller. Then, if you hit the reset on the controller, everything seems to reset OK, the code error light goes out, but then a spike relay will start cycling at about 1 Hz, sounding like an old car turn signal. Turning off the robot, and starting back up, sometimes will clear the condition, but most times it wouldn't. Moving the joystick all the way to one side (I think to the left) makes the relay stop. I'm not sure if the trigger still operates the relay (we modified the Kevin.org code for relay controls and some PWM control shaping)

The other symptom during this time that prior to the reset, the main battery voltage indicates OK on the controller (over 12 VDC). But when the relay is clicking, the battery power display shows about 8.2 VDC, even though during that condition, we metered the battery terminals, as well as the power going into the controller, and got over 12 VDC.

So, can anyone explain the incorrect battery voltage? I'm looking through IFI reference documents, but haven't found anything yet. We have since reloaded the streamlined code, with fewer changes, and are waiting to see what happens. To my knowledge, we're using the firmware on the controller that came with it, no updates have been loaded that I know of.

Also, I found one explanation about code error, is there a more detailed description of it anywhere?


Thanks
Ted