Fatal Error (D0001) Cpu Error / Illegal Command Structure

[James]

Earlier today, I was editing a pc program on a Kawasaki D Controller. I had aborted and killed a PC program do do the edit and after typing the command into the editor: "SOUT 2010 = 83 AND 87" the robot crashed with the error "(D0001) CPU Error - Illegal Command Structure." I've managed to get it going again but does anyone know what I did wrong? I've seen a similar SOUT instruction in the original PC program from when we first got the robot.

[roboperson]

The error references a CPU problem with your 1KA / RA board or software. I dont think it is something in your code, it sounds more like a hardware issue like your CPU could be going bad, or possibly noise. When the error occured you should have gotten a code. D0001 code XXXXX . You should be able to contact Kawasaki with that code and they should be able to tell you where the error occured? Other than that, make sure you have a good all data save so if you lose your CPU you can load it back in if it fails.  Best of luck .

[James]

Thanks for the info roboperson, I've set the controller up to autosave every day at midday just in case. 

[rdixiemiller]

 I spend hours each day programming these controllers, some of them just crash on occasion. If you start getting lots of error messages when you are saving and downloading, initialize the controller and reload it. Trust me, some are just buggy this way. It seems to have something to do with how the original software package was loaded. I always make a backup at the end of the evening, and each morning when I am on-site doing a job. That way I always have a recent backup to reload if needed. What program were you using, KCWINTCP or KCWIN32? I seem to have more problems with the ethernet version.

[James]

I wasn't actually using KCWin32 until after the robot crashed. I only used it to recover as the controller could boot up (got stuck at the "Simple and Friendly" splash screen). I was using the built-in program editor.

[rdixiemiller]

 You were programming on the keyboard screen?
 I ran into a problem a while back on a D controller, KRI is working on a patch right now. If you ended up with 148 or 149 empty spaces on a line, the CPU would lock up hard. The problem was caused by a comment that had been moved way over to the left, sure was irritating to hunt down!
 As I said, some of these controllers are just a bit quirky.

[James]

Thanks for the help, just heard back from the integrator who helped set up our other robot and apparently he gets the same problem at least once a year. He tells me as well that the only way to recover is to initialise the system and restore from backups.

So if anyone else is reading this, remember to keep backups.   

[rdixiemiller]

 It goes without saying, ALWAYS keep a backup of your robot! No matter what brand or model, they can get corrupted files. Backups are quick and easy insurance. I have 30 or so that I keep backed up, usually monthly, all over the country. The internet is grand!