Author Topic: Problems after RAM battery replacement with FS03N  (Read 627 times)

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Offline jjbb

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Problems after RAM battery replacement with FS03N
« on: March 14, 2018, 03:51:12 PM »
Hello all,
I am having some issues with a robot FS03N and a controller D73.
The problem is similar to other topics:
The teach pendant is frozen after dead RAM battery replacement.
I open the controller and push the jumper nº 8 to on. After, I turn on the device and sel. 999 and force the data. After, I tried to recover configuration from a file.
But some errors are showed:

At first place, failed to load arm data (D2023)
After, D1017 “Error of download of servo data” and D1016 (Data applicable to the robot model not in servo file)
And, of course check sum error (E0903) and don’t working «Motor power ON».
When I tried to recover data from a backup, it is showed “File load completed” but whit 150 errors.

Also the procedure is different if I do from the teach pendant or from RunPcAs.exe. At the first case, all SW version in aux menu 0804 is filled, but from PC, Arm data file and SERVO GROUP are void.
The problem is that I Can´t recover data from teach, only from PC, isn´t it?

When the teach finish starting, the leds of “cycle start” and “motor power” goes to OFF. And are not able to back ON, even if I press the red switch on 1 KP board.

If I push RE24V yellow button and another red button of the 6 axis, I can hear a relay and move the axis.

Here is the beginning of the backup file:
.***************************************************************************
.*=== AS GROUP ===         : AS_R1B0030Y 2007/05/15 11:36
.*USER IF AS               : UASR1B0030Y 2007/05/15 11:09
.*USER IF TP               : UTPR1B0030Y 2007/05/15 11:27
.*ARM CONTROL AS           : AASR1B0030Y 2007/05/15 11:32
.*USER IF AS MESSAGE FILE  : MAS1B030YEN 2007/05/15 11:33
.*USER IF TP MESSAGE FILE  : MTP1B030YEN 2007/05/15 11:36
.*ARM DATA FILE            : ARMR1B0030Y 2007/05/15 11:33
.*USER IF IPL              : UIP02060000 2007/04/05
.*ARM CONTROL IPL          : AIP02060000 2007/04/05
.*=== SERVO GROUP ===      : SV_R5000004 2007/08/21 08:38
.*ARM CONTROL SERVO        : ASVR5000004 2007/08/21 08:37
.*SRV DATA FILE            : ASPR5000004 2007/08/21 09:09
.*ARM CONTROL SERVO CONT.  : ASCR5000004 2007/08/21
.*ARM CONTROL SERVO FPGA   : ASFR5000002 2007/08/21 08:20
.*   [Shipment setting data]
.*There is no Shipment setting data.


If I tried to save R2, here is the beginning of the file:
*=== AS GROUP ===         :
.*USER IF AS               : UAS0180020Z 2006/09/27 09:46
.*USER IF TP               : UTP0180020Z 2006/09/27 09:47
.*ARM CONTROL AS           : AAS0180020Z 2006/09/27 09:49
.*USER IF AS MESSAGE FILE  : MAS10020ZEN 2006/09/27 08:51
.*USER IF TP MESSAGE FILE  : MTP10020ZEN 2006/09/27 08:55
.*ARM DATA FILE            :
.*=== SERVO GROUP ===      :

(I can save without problems, not like https://www.robot-forum.com/robotforum/kawasaki-robots/fully-discharged-ram-battery-corsed-no-ability-for-motor-power-on/ )


Any ideas or suggestions?  Thanks in advance!




Online kwakisaki

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Re: Problems after RAM battery replacement with FS03N
« Reply #1 on: March 14, 2018, 07:13:52 PM »
You will need to contact your local distributor for AS and SV files and procedure to load in.
It appears from your explanation, your backup references later AS/SV versions than the current AS/SV files after your re-initialisation.
- This will explain the 150 errors you have received during file load.

Try ZROBOT via keyboard/PC to select proper Arm Model, this may allow you motion and basic setup.
Get backup you tried to load before, go into a text editor (like notepad) and remove all data between .ROBOTDATA1 and .END and try and reload it.

Offline jjbb

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Re: Problems after RAM battery replacement with FS03N
« Reply #2 on: March 15, 2018, 11:41:07 AM »
Hello,

Thank you for your answer.

I have contacted with Kawasaki Germany asking for SW config.

If I try to use the command ZROBOT through Teach Pendant, are showed the errors E1030 and E0903 but it can be reset.
but the motor power doesn´t go to ON.

If I delete the data between ROBOTDATA1 and the first .END, I "only" get 115 errors.

Anyone has a basis configuration for this config?:

Kawasaki Robot controller:   Model D70F-D001
Kawasaki Robot:  Type FS003N e 

Another problem is that the result from PC o from Teach isn´t the same, and I can´t load files from teach, only PC way.

Thanks again!



Online kwakisaki

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Re: Problems after RAM battery replacement with FS03N
« Reply #3 on: March 15, 2018, 06:41:12 PM »
E0103 (Joint xx abnormality Error) is saying the joint value(s) being received from the encoder, are different from when it last powered down.
- This is a resettable fault and is usually down to system initialization or possibly brake failure.
- However, since you have re-initialized the Controller this would be normal.

E0903 (Check Sum Error) is just comparing check sum values, again normal after a re-initialization.
- Can be cleared with command of CHSUM in keyboard, or via Aux 0803.

Motor power may not be achievable because of safety circuit (Ext EStop, Ext Trigger, Safety Fence Connections) or permanent displayed error.
- Check for no permanent error......try and reset, if not possible, (error dependent) then Motor Power not possible - report back permanent error.
- Check 1KP Board X7 and X8 configuration.
- As standard, Controllers are shipped with Safety Circuit jumpered to allow immediate Motor Power and motion.
- Please check/confirm X7 for 1-2......3-4........5-6......7-8 (Ext EStop).
- Please check/confirm X8 for 1-2......3-4 (Safety Fence) and 5-6........7-8 (External Trigger).

If you can achieve Motor Power, then motion should be possible.

To re-zero temporarily:
Aux 0503 - Encoder Rotation Counter Reset
- Reset all joints to 0.
- This should allow motion to scribe lines.

When moved all to 0 then:
Aux 0503 - Encoder Rotation Counter Reset
- Reset all joints to 0
Aux 0501 - Zeroing
- Reset all joints to 0.

This should complete zeroing, if Joint abnormality reappears after a power down/up.....then check Encoder Battery in Robot Arm (behind black cover where harness connects to robot) and replace (When Power is OFF).
- You may need to carry out re-zero again, if it takes you longer than 30 mins to replace battery.
« Last Edit: March 15, 2018, 07:04:46 PM by kwakisaki »

Offline jjbb

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Re: Problems after RAM battery replacement with FS03N
« Reply #4 on: March 19, 2018, 08:40:43 AM »
Hello,
Thanks for your answer.

I ´ve contacted with Kawasaki support. Following its instructions, I ´ve downloaded a new AS and SV software (the last one's versions).

After that, I obtain the errors W1013, E1013 and 0903. All of them are resettables.
After, I obtain a warning: W1013.

Still in contact with the support, but, what do you mean for:

 Please check/confirm X7 for 1-2......3-4........5-6......7-8 (Ext EStop).
- Please check/confirm X8 for 1-2......3-4 (Safety Fence) and 5-6........7-8 (External Trigger).

The motors have power and pair, and it is no possible to move them if I don´t press the brake release SW and RE24V SW.

By the way, Cycle start" and "motor power" LEDs are ON when the main power button is pressed until the Teach pendant is completely started.

Best regards

Online kwakisaki

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Re: Problems after RAM battery replacement with FS03N
« Reply #5 on: March 19, 2018, 09:41:22 AM »
Quote
- Check 1KP Board X7 and X8 configuration.
- As standard, Controllers are shipped with Safety Circuit jumpered to allow immediate Motor Power and motion.
- Please check/confirm X7 for 1-2......3-4........5-6......7-8 (Ext EStop).
- Please check/confirm X8 for 1-2......3-4 (Safety Fence) and 5-6........7-8 (External Trigger).

The above describes the standard safety configuration (wiring interface) shipped as default with all Kawasaki Robots.
- If you cannot achieve MOTOR POWER ON (Orange) light on front of panel, and there are no errors then usually because safety circuit is not wired correctly on X7.
- X8 Configuration is for Safety Fence (Repeat) and External Trigger (Teach), if either of these is missing, then Robot motion is not possible in respective modes.

From what you describe:
Quote
The motors have power and pair, and it is no possible to move them if I don´t press the brake release SW and RE24V SW.
It reads that you can get motor power on now.....Correct?

Quote
By the way, Cycle start" and "motor power" LEDs are ON when the main power button is pressed until the Teach pendant is completely started.
- This occurs during bootup and is normal.
- Until Robot has completed bootup, you cannot use Teach Pendant.

You need to replace Encoder Batteries in Arm - The errors are telling you of low encoder battery.
- Battery is located behind rear black panel (where main harness connects to Robot).
- Replace this (when power is off) and carry out zeroing procedure as I described.

When you have done this, you will be in a position, where your previous backup could be used (without the .ROBOTDATA1 and .END) in order to return the Controller as close to the original Controller Configuration (same as your backup) as possible.
« Last Edit: March 19, 2018, 10:01:21 AM by kwakisaki »

Offline jjbb

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Re: Problems after RAM battery replacement with FS03N
« Reply #6 on: March 19, 2018, 11:18:05 AM »
Quote
- Check 1KP Board X7 and X8 configuration.
- As standard, Controllers are shipped with Safety Circuit jumpered to allow immediate Motor Power and motion.
- Please check/confirm X7 for 1-2......3-4........5-6......7-8 (Ext EStop).
- Please check/confirm X8 for 1-2......3-4 (Safety Fence) and 5-6........7-8 (External Trigger).

The above describes the standard safety configuration (wiring interface) shipped as default with all Kawasaki Robots.
- If you cannot achieve MOTOR POWER ON (Orange) light on front of panel, and there are no errors then usually because safety circuit is not wired correctly on X7.
- X8 Configuration is for Safety Fence (Repeat) and External Trigger (Teach), if either of these is missing, then Robot motion is not possible in respective modes.


From up to bottom, there are bridges with blue wire in 1KP:
First connector: 1-2,3-4,5-6,7-8
Second: 1-2,3-4,5-6,7-8.  Not: 9,10,11,12
Third: 3-4,7-8,9-10,11-12   Not: 1,2,5,6



 

From what you describe:
Quote
The motors have power and pair, and it is no possible to move them if I don´t press the brake release SW and RE24V SW.
It reads that you can get motor power on now.....Correct?


No, I don´t mean that. Sorry.
In the controller there are some SW at the front: one per each axis and also one button red labeled "RE24V"
If I press one SW and RE24V, I can move the robot manually, is like a clutch.



Quote
By the way, Cycle start" and "motor power" LEDs are ON when the main power button is pressed until the Teach pendant is completely started.
- This occurs during bootup and is normal.
- Until Robot has completed bootup, you cannot use Teach Pendant.

You need to replace Encoder Batteries in Arm - The errors are telling you of low encoder battery.
- Battery is located behind rear black panel (where main harness connects to Robot).
- Replace this (when power is off) and carry out zeroing procedure as I described.

When you have done this, you will be in a position, where your previous backup could be used (without the .ROBOTDATA1 and .END) in order to return the Controller as close to the original Controller Configuration (same as your backup) as possible.


But, despite the fact that battery is low, ¿it would possible to power motors? Because, there is a failure of encoder, not power, or are relational?

Thanks!

Offline jjbb

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Re: Problems after RAM battery replacement with FS03N
« Reply #7 on: March 19, 2018, 03:02:59 PM »
Problem solved.

Thank you so much.

I hope that my experience could help anyone.

Online kwakisaki

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Re: Problems after RAM battery replacement with FS03N
« Reply #8 on: March 19, 2018, 03:50:21 PM »
Your configuration for 1KP looks ok.....as standard.....So I expect encoder error is preventing motor power.

Usually when Encoder related problems exist, because of unknown position (safety related), they prevent motor power.
- This will still allow manual brake release via buttons.

Motor Power is not physical power, it is part of safety circuit activation to allow servo energize, check feedback from amplifier circuit is good, then release brakes.

Glad to hear your problem is resolved..... :top: