AD Controller error number 1102

[najafabadi]

Hi everybody,
I can start an old Kawasaki JS-2 FA 60 after ages!
Now please have a look at the attached photo. I think the number 1102 should be the error number. I found from the error manuals (available in the link http://www.kawasakirobotics.com/srchdatabase/sessearch.cgi?ae=%C3%9F&q=Manual&op=and ) that should be I/O bus error.
Can someone help me to solve this problem?
Many thanks in advance for your help.

[roboperson]

The 1102 is a VME Bus error. Most likely a bad CPU (9ZA board). If you pull the board and look, have the batteries exploded on it or corroded? It could also be a software issue, but if the chips are present, then its more than likely a bad CPU, or the batteries on the backplane have exploded, causing the same issue.
If the boards are clean, and no corrosion, and if you have a data sheet or all data save, you can try to initialize the CPU. Sometimes this will clear the error, but once you start getting bus errors, normally, the CPU is shot.

[najafabadi]

Thank you Roboperson.
I opened the controller's case and noticed that some red LEDs on the EA boards are on. EA board has 2 groups of 6 green LED and 6 red LED located in the above and below of this board (total number of LEDs are 12 reds and 12 greens).
Please let me know the meaning of the LEDs exist in the AD controllers' EA board.
Also please have a look at the attched photoes of the EA board.
Many thanks in advance for your help.

[najafabadi]

Hi again,

I think I made a mistake in number of LEDs on EA board. By the way the description of the LEDs on the PCB of main CPU of our AD controllers show that from the red group we have BUS and SRST LEDs light on and from the green ones we have VCCs and RUN LEDs light on.
Any guidance or opinion?

[roboperson]

The 9ZA board is  the CPU. the 1AE board is your break break board. Your main concern at this point is with the 9ZA and having the 1102 Bus error, and not  being able to boot up properly. The 1AE board does not generate this kind of error. There has to be some problem between the 9ZA (main CPU) and 1HZ (Card Rack, Motherboard.) You may be able to initalize the controller to get around it for a short time, but it will return at some point. If the batteries on either board have not exploded, and there is no other corrosian on the traces, no bent pins where the board mounts to the mother board, then the mortherboard, 9ZA, or software chips are bad.

[najafabadi]

Thank you Roboperson for your great help. I open the controller completely and check pins and tracks and batteries. Nothing special found but after I assembled the controller again the first screen changed as the attached file. Although the error still exist and the red LEDs remain unchanged as before but I haven't the error number on the screen now. What is your opinion about this condition?

[roboperson]

If you have a data sheet, or all data save on a disk, then you probably should try to initalize the controller. This would probably put you into a default state, but you would have to either manually enter the data, (robot type, I/O signals, etc) manually. If you have a save on a disk, it would have all this information. You can initalize by flipping dip switch 8 on the 9ZA board, and cycling power. It will ask if you want to initalize. Follow the promps. As I said, this will take it to default information, and you will have to enter the information manually, or by disk but it would probably be further than you are now. After you initalize, turn the switch back off.

[najafabadi]

 
Thank you, thank you, thank you Roboperson very much. Today something good happens.
When I set the dip switch 8 on CPU board on and reseting the controller, Japanese setting questions displayed .
Please see the attached picture.
Now I have 2 problems, first I haven't the setting manuals and second I'm not familiar with Japanese language!
Please help me to set the parameters. Many thanks in advance for your help.

babak.najafabadipour@gmail.com

[roboperson]

Something just isnt right. Do you have all 4 eprom chips on your 9ZA board for software? It almost seems as if your missing a chip, have corrupt software which is possible, but unusal being they are eproms, or a bad 9ZA board.

[najafabadi]

The previous picture dosn't show the first screen. I think in that picture I pressed a key (I think it should be ESC key) 4 times!
The ECU has 4 EPROM.
I attached more photos about the screens.
What's your opinion. Many thanks in advance for your helps.

[roboperson]

The 1511 error shown is encoder batteries. Im not sure if the controller is hooked up to the robot or if the encoder batteries themself are low? Im not sure where your controller came from? On the panel that you are taking screen pictures from, there is butons for AUX, and Data. Are they in english, or are the buttons on the Panel in Japanese? You may need to contact Kawasaki to ask them if the software ROM chips that you have are for English or Japanese? If the version is for English, and since you dont have an optional keyboard, then if there is a function to change from Japanese to English, you would have to dig through the settings to find it. The second picture that you showed has the cartesian coordinance of where it is. To the right is the motor power and hold indicators, so your into the main screens. By pressing the AUX buttons, and Data buttons, you should have different numbered menus. Im not sure where your at, at this point?

[najafabadi]

Thank you Roboperson for your answers and your great help. I should try more.

By the way can somebody send me the setting manuals of an AD controller?
Many thanks in advance for your help.
 
babak.najafabadipour@gmail.com