Password protection and arc weld issues

[sulcy003]

Hello,

We have purchased a second hand FS20N.  When I turned on the controller, a keyboard appeared on the pendent screen as if a password was needed to use the teach pendant, I have no idea how to get past this.  On the other FS20N we purchased a password level was required to access some of the auxillary functions, however I initialised the robot and now have full access.  In doing so I seem to have severed a connection between the welding card and the welder controller.  The machine will attempt to strike an arc but no signal will come from the welding card to the welding controller interface.  Also I have connected a laptop to the working welder and run KC win but I have no idea how to use this software - are there any manuals other than the help section available for this?  Any help with these issues would be greatly appreciated.

Cheers Chris

[roboperson]

The reason you had the keyboard screen was you lost meomory. By initalizing. It, you got past it which is the correct step, but you probably lost robot type/ aux data/ i/o / etc. You either need an all data save or a data sheet to set it up, or you need to get a data sheet from kawasaki. The data sheet SHOULD be in the contoller, but is hit or miss. I'm sure you don't have correct data, S-logic, or your aux data set up correct. If the mentioned is correct, then I would question if S-logic is running?  best of luck

[SkyeFire]

If your two robots are the same in their I/O setup with their welding systems, you can probably copy most (all?) of the settings from the good robot to the bad one. 

Probably the best way to do this is grab the Kawasaki manuals available at http://www.robot-forum.com/robotforum/kawasaki_robots/d_controller_operations_manual-t3316.0.html, particularly the AS reference manual.  Then make a full backup of each robot.  Pull the backups onto a computer (they should be .AS files, which are simply text files that contain most of the settings in a Kawasaki), and compare them using a program like UltraCompare (expensive) or KDiff3 (free).  You'll have to work out which differences are important (the AS language manual will help here).  One of the nice things about Kawasakis is that you can add/remove chunks to an .AS file, then load it back into the robot -- as long as you have the syntax and the header/footers correct, it'll take.  You can copy programs or certain settings between robots this way.

You could also put the teach pendants side-by-side and go through all the setup menus, setting the new robot to match the old one.

One thing:  the SPG program runs on a separate board from the "main" program board (actually, the SPG runs on the I/O board).  The SPG program you see in your .AS file is a text "source code" file that resides in the main board's memory, but the SPG that runs is a compiled version that runs on the I/O board.  This means that if you copy the SPG program from one robot to another, or make an edit to the SPG program, you have to complete one more step to have the new SPG actually running: download the SPG from the main board to the I/O board.  There's an Aux menu function that will do this.  You can also do it using the command "sd" from the terminal screen or over KC-Win.  You will have to Stop the SPG, then Download, then Start it again.

The sections of the AS Reference Manual that deal with Editor Commands and Monitor Commands will tell you a lot about how you can use KC-Win and/or the terminal screen on the pendant.  Using KC-Win is a lot like logging into an old 1970 mainframe over a serial terminal, but it can be very handy for troubleshooting and code debugging.

[Kwak]

Hi There,

Check your private messages, i have actually worked on these units!!!

Let me know if you need more assistance.

[rdixiemiller]

 If there is a backup on the PCMCIA card, you can pull it and reload the settings. I have a cloning macro that runs in UltraEdit. I use it to strip the robot specific data from a backup to image another controller. It is extremely useful when setting up several identical robots.