vkrc2 krc 4.1.6 cannot jog/master

Hey All,

Looking for a little guidance here. I know there have been a few posts on here regarding this, but I cannot find how people diagnosed the problem:

Controller turns on fine and boots up. Proper changes have been made to allow for motion and the such including the GM safety bypass plug properly jumpered. All of this is done in T1 mode as an expert user. The control cabinet is a GM vkrc2 circa 2003 running on krc 4.1.6.

I pull the deadman switch (yes halfway), wait for drives, and when I go to jog the robot...error city.

It "usually" goes like this:

1245 quit servo bus disturbance DSE 1
1216 ackn drives error A1-6 No. TRIP

and sometimes it throws
1229 Ackn watchdog power module PM1
and some others related to power module every so often related to low voltage of pm1.
No communication errors or anything...

I thought it might be the cable from DSE to KPS, but when I pull that it throws different errors.

Any way to diagnose the power module simply or suggestions on best place to start? I should also add this robot was delivered missing the mfc/dse card and that they were replaced from a different robot. I'm wondering if that couldn't have something to do with this. Thanks.

DJ

I forgot to mention two more things:

1. Both red and green light are on and constant on the RDW card.

2. Under ESC monitor I get -->
Fatal error execution terminated
ESCInternalERR13
Possible reason: missing power supply or ESC hardware defect.

The gm cabinets don't have typical krc2 ESC board now ESC connector from kps600 as seen in my photos above. On the wiring diagrams provided with bot I don't see any reference to ESC relays.

Anyone with a gm vkrc2 care to clue me in? This is a kr200 arm. Thanks.

That is...there's no ESC board nor x14 connector from the KPS600 to the non-existent ESC board. There is the CC1 plug to the fe207/208 boards.

Can anyone with a GM vkrc2 run MONITOR --> DIAGNOSIS --> SECURITYCIRCUIT and take a picture of what they see? I would greatly appreciate it.

When I run the DSE/RDW/MFC TOOL and go to drivebus diagnostic menu I can monitor voltage of the intermediate circuit with deadman engaged and off. I have about 575V at KSP and KSD 1-6 with deadman engaged. All drives are "ok". So, I'm ruling out needing to replace the KPS600. I have attached an image of the MFC display register. Again, I'm not sure what normal on this should be. Any input would be of great help.

The fault code that I'm getting after activating drives is 1245 quit servo disturbance DSE1. I'm just trying to piece together where this could be coming from. Green LED is blinking on the DSE, as noted, there is communication between DSE and RDW. I have power at the KPS and all KSDs. Seems to be something in the security circuitry. But I'm not getting any errors that are indicating what exactly. DSE and and MFC were replacements from another bot...do I need to sink DSE MFC and RDW?

I activate drives with the deadman switch, go to jog, and receives errors (after voltage is present). The top green light on the KPS600 goes from blinking green to constant green (indicating proper voltage) but the bank of 4 leds (2 green 2 red) never light up. $GM_WO_PLC set to true, MOVE_ENABLE at 1025, LPDN scanner commented out.

I have attached pertinent pictures of screenshots including a layout of my cell i/o. Thanks to anyone reading this and giving any amount of brain waves.

DJ

Forgot one...

Thanks skyefire. By the k1 you are referring to the g1/k1 on the kps600? If so then yes. When I monitor the kps voltage it goes from 23v to 575v after pulling the deadman switch. This happens after k1 closes.

It does throw pm1 under voltage and watchdog pm1 errors sometimes. I'll get the codes when I'm back by the bot later and post pics.

Any way to troubleshoot that?

Thanks again.

1223 ackn under voltage pm1
1201 quit buffer battery voltage low pm1
1229 ackn watchdog power module pm1

I only get these when trying to jog the robot.

When I open the master dialogue and try to jog I don't get them.

I did install new batteries.

In regard to tracing down leds on the fe207/208:

Number one:

6k2 on fe207. Associated led is dark (v54) traces back x807 pin 30 on MFC. drives on MFC.

I've attached a picture of it and the wiring.

Please see picture of MFC input register. 1st pic is without deadman. 2nd is with it pulled. Where can I find the register output code meaning?

Number 2:

8k1 8k2 8k3 on fe208. 1 and 2 are not lit up and 3 is red. I've attached picture with wiring. These are for external auto stop so doesn't seem pertinent.

I've been reading over this post: https://www.robot-forum.com/robotforum/kuk…-help-urgently/

Seems like it could be power module, rdw, dse, kps, cables, ksds...I think I've narrowed the field a bit.

Skyefire...by power module you are referring to the KPS600, correct?

Like I said, I do get voltage at the KPS but my guess is this has something to do with the internal logic. There are two banks of LEDs on it. The top being one red and one green. Red does not light up (except on boot up) and green blinks until K1 closes and then is constant green until voltage goes back down. The other bank, two red two green, never lights up. No blinking, no anything.

Thanks PanicMode.

I just want to clarify that KPS600 and PM1 are in fact referring to the same thing...

Caveats. Thanks for the help.

I'm swapping it out next week. From reading all these posts seems like quit servo DSE 1 errors end up pointing back to the KPS. I'll find out soon enough.

Replaced the KPS and she moves. Thanks for all the help.