C Series - AC Primary Power OFF

    See Photo.

    My C series controller was fully operational, I went to power it on Tuesday and the controller will not load past the initialization screen.
    It doesn't throw any errors, just says AC primary power OFF.

    Error 1800 reads AC primary power off.

    I have checked all of my voltages on the transformer side, and the AVR appears to be functioning correctly.

    I swapped my 1HP and my 1GA board.

    All of the voltages on the test points of the 1GW and the 1GA boards are correct.

    I have voltage on my 1GB board. Should TP3 and 4 be reading voltage?

    Sounds like could be:
    1. RAM Battery exhausted.
    2. 1GA Board Failure, corrupt data, loss of firmware, incorrect firmware.
    3. Teach Pendant Software on 1GA board incorrect version/incompatible with installed AS or software on 1GA board is corrupt.
    4. Teach Pendant failure - although you say that you re-initialize and it managed to complete boot up (so would not consider Teach Pendant to be bad).

    With you hardware initializing it, with dipswitch 8, then no robot model information is stored in controller.......
    - Check AUX FUNCTION 90
    - Robot Model is stored here usually - when initialized with dipswitch 8, then this data is removed.
    - Resulting in empty controller with no robot model information or user data.
    - If you have previous backup - reload it and should restore information.
    - Turn Dipswitch 1 on and the rest off for normal operation.

    But, if different 1GA.....then you may need to load the 1GA with correct firmware (AS, SV and TP) and then load in previous backup to restore.
    - Also would recommend to replace the RAM battery pack too.

    Thank you,

    That confirms what I'm working towards.
    I attached a picture of my aux 90.

    Unfortunately, I don't have a backup and I don't have the PC Cards for any of my C Series robots. :wallbash:

    But I do have 1 C series that is the same model and robot, can I download the program info off it (using a computer & serial cable) & upload it to my broken robot?

    I know somehow I would have to change the serial number of the robot?

    Also, where is the ram battery located? I cant find it in my electrical maintenance manual.

    Hmmmm, AUX 90 has a robot model in it......I wasn't expecting to see that after a 'dipswitch 8' initialize.......I would expect to see that empty..... ???
    - Is the Robot Model ZX130 the same as the Physical Robot it's connected to?
    - If not, that maybe why the Servo error is generated.....
    Makes no difference though.....just strange. ???

    On a backup, the robot model/serial no. and zeroing as well as the other system data are in there, so ordinarily you would be 'cloning it' with the same details as the one the backup has come from.
    - So by uploading/downloading that data to this Controller is basically the same as removing the 1GA from that Controller and fitting it in this one.
    - Just need to remember that you will be re-zeroing this Controller with the copied data zeroing.......so you will have to re-zero it for sure.
    - Also, other settings may need to be changed to, such as upper and lower limits, dedicated signals, IF Panel settings etc as these will be from the other Controller.
    - So could be a long winded process to get it back to the original condition......but not impossible.
    - Serial no. is not real important......but nice to get it back to same data on rating plate.
    (Dam shame you don't have a recent backup of it though and PC Cards.......)

    The RAM Battery is usually located on the side of the left outer shell of the Card Rack File, tie wrapped to the side.... (The rack where the 1GA/1HP boards are fitted).

    Hope this helps.........

    Thanks kwakisaki,

    I also have to give a shout out to Kawasaki's customer support, cant say enough good things A++.

    I ended up using KRterm to download the data off my running C series controller/robot. Then uploaded it to my broken controller/robot. When I rebooted I selected the option to load off the robot/arm data. This seems to have straightened out my problems.

    Its still giving me a ram battery low error, but I have replacement batteries on the way.

    Good man, glad you've got it 99% sorted and thanks for the feedback.
    - Nice also to hear that an OEM customer support have proved useful.
    - I do think Kawasaki Support is very beneficial from experience......so always worth dropping them a line from time to time.

    As long as you don't power the Controller off, the RAM battery error should not effect you.
    - Even when it comes to replace it, I think the 1GA board has a backup Capacitor that gives you a 30 min window to change it when you do power it off.
    - But, if you have backed it up anyway, wouldn't matter if it did.

    ......................... :beerchug:....................

    Could be anything.......so provide more details and may be we can assist further.
    - For future, recommend starting a new topic.

    Is this a spare or production unit, when and how did problem appear, after shutdown period (if so how long off), during operation, when was battery last replaced in Controller, have any boards been replaced, have any software or backups been loaded in, what attempts at fixing it have you tried................the list continues............

    So if you can provide more details, may be we can assist you.

    Hi

    I have as c series controller that displays the same screen as the first post in this thread, however the only message it says is - AC then a few Japanese words.

    how do I turn it to English?

    (the controller has been in storage for approx 7 years so I assume it has lost it's memory by now)

    Thanks

    It sounds like AS and TP software is mismatched.
    If the Controller has indeed lost it's memory, then you could try full initialization and see if it comes back, but I suspect not.
    - You would need to obtain the original AS and SV firmware to reload into the Controller first.
    - Without especially AS, communication between Teach Pendant and Controller is not possible.

    ok, so I have got the robot to respond to the teach pendant,
    I don't have the pc card or back ups for this robot,

    there seems to be a lot of the options & functions similar to the working robot I have. and the details I can read in AUX 90 match the working c series robot I have,

    the biggest issue I have at the moment is I don't understand Japanese, is there an option/setting or switch to change this? I've been searching through manuals etc but I can't find anything on display language,

    I've attached some pictures of what I've got going on.

    Thank you

    See attached images:

    img1 - access the keyboard
    img2 - enter command ZLAN ON and exit keyboard function
    img3 - result is English

    Hope this helps............

    Boa noite

    Marlon

    Welcome to the forum.............:beerchug:

    Please start a new thread and include the following information:

    - Full Controller Model/Series No.

    - Full Robot Model No.

    - If you have a file save from when it was working.

    - Screenshots of Aux Func 90.

    - Screenshots of any other errors displayed (INCLUDING DESCRIPTION NOT JUST THE NUMBER).

    - What you have tried to do to resolve the problem - be very specific.

    - Have you read any supporting documentation like a troubleshooting manual.

    - Have you got any spare parts for it.

    - What history there is associated with the robot - ie what previous application, health issues, condition.

    - Any other information you may consider relevant.

    - Optional supporting photo of the inside of the Controller.

    Just asking a question that states 'I have the same problem, my robot is not initializing', is not very helpful.

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